Air filter cartridge and air cleaner assembly

ABSTRACT

An air filter arrangement is disclosed. The air filter arrangement includes strips of media comprising fluted sheets secured to facing sheets and forming inlet and outlet flutes secured to one another in a stack. Media pack arrangements including such stacked media with peripheral, perimeter, housing seal arrangements are described. Also described are air cleaners including the filter cartridges. Methods of assembly and use are also provided. Also, systems of use are described.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is being filed on 12 Jul. 2007, as a National StagePatent Application of PCT International Patent application numberPCT/US2006/001061 filed on 12 Jan. 2006 in the name of DonaldsonCompany, Inc., a U.S. national corporation, applicant for thedesignation of all countries except the US, and Gregory L. Reichter,Wayne R. Bishop, Benny Kevin Nelson, Darrel Wegner, Bruce Crenshaw,Vladmir Kladnitsky, Thomas G. Miller, Donald Raymond Mork, KevinSchrage, Richard J. Osendorf, Bradley A. Kuempel, Thomas John Lundgren,and Jordan S. Flagstad, all citizens of the US. The present applicationincludes the disclosure of, with additions, U.S. Provisional Application60/651,838, filed Feb. 8, 2005. The complete disclosure of U.S.Provisional Application 60/651,838 is incorporated herein by reference.A claim of priority to U.S. Provisional Application 60/651,838 is madeto the extent appropriate. A claim of priority to U.S. ProvisionalApplication 60/644,094, filed Jan. 13, 2005 is also made to the extentappropriate.

FIELD OF THE DISCLOSURE

The present disclosure relates to filter media for use in filteringgases. The disclosure particularly relates to media packs that usez-filter media which comprises a corrugated media sheet secured tofacing sheet, formed into a media pack. More specifically, thedisclosure relates to such media packs and their inclusion inserviceable filter cartridge arrangements, typically for use in aircleaners. Air cleaner arrangements, methods of assembly and use, andsystems of use are also described.

BACKGROUND

Fluid streams, such as air, can carry contaminant material therein. Inmany instances, it is desired to filter some or all of the contaminantmaterial from the fluid stream. For example, air flow streams to engines(for example combustion air) for motorized vehicles or for powergeneration equipment, gas streams to gas turbine systems and air streamsto various combustion furnaces, carry particulate contaminant thereinthat should be filtered. It is preferred for such systems, that selectedcontaminant material be removed from (or have its level reduced in) thefluid. A variety of fluid filter (air or liquid filter) arrangementshave been developed for contaminant rejection. However, continuedimprovements are sought.

Certain of the techniques described herein are related to thosedescribed in U.S. Provisional Application Ser. No. 60/599,686 filed Aug.6, 2004; a complete disclosure of which is incorporated herein byreference. The present provisional application also includes sometechniques described in U.S. Provisional Application Ser. No.60/600,081, filed Aug. 9, 2004, the complete disclosure of which isincorporated herein by reference.

Further, the present provisional application includes certain thetechniques in U.S. Provisional Application Ser. No. 60/602,721 filedAug. 18, 2004; the complete disclosure of which is incorporated hereinby reference. Also, the present provisional application includes certainof the techniques described in U.S. Provisional Application Ser. No.60/616,364 filed Oct. 5, 2004; the complete disclosure of which isincorporated herein by reference.

SUMMARY

According to a portion of the present disclosure, features useable inpreferred filter cartridges, such as air filter cartridges are provided.The features can be used together to provide a preferred filtercartridge, however some advantageous cartridges can be constructed touse only selected ones of the features. In addition, methods ofconstruction and use are provided.

In one aspect of the present disclosure, a preferred media pack isprovided, for use in, or as, an air filter cartridge. The media packcomprises a stacked z-filter arrangement having opposite flow faces andopposite sides. At the opposite sides, ends of stacked strips aresecured in, and sealed by, molded end (side) pieces. Typically themolded end (side) pieces are molded-in-place and comprise moldedpolyurethane. Also, a useful molded-in-place seal arrangement is alsodescribed.

Also air cleaner arrangements which use the filter cartridge as aservice component are also described.

Various preferred features for a filter cartridge, for a described typeof application, are shown. In addition, shown and described arevariations in air cleaners and air cleaner systems. Also, methods ofassembly and use are shown and described.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fragmentary, schematic, perspective view of z-filter mediauseable in arrangements according to the present disclosure.

FIG. 2 is an enlarged schematic, cross-sectional view of a portion ofthe media depicted in FIG. 1.

FIG. 3 is a schematic view of examples of various corrugated mediadefinitions.

FIG. 4 is a schematic view of a process for manufacturing mediaaccording to the present disclosure.

FIG. 5 is a schematic cross-sectional view of an optional end dart formedia flutes useable in arrangements according to the presentdisclosure.

FIG. 6 is a schematic depiction of a step of creating a blocked, stackedz-filter media pack.

FIG. 7 is a schematic top perspective view of an air cleaner assemblyincluding features according to the present disclosure.

FIG. 7A is a schematic top perspective view of the assembly depicted inFIG. 7, from a generally opposite direction.

FIG. 8 is a side elevational view of the assembly of FIG. 7; thedepiction of FIG. 8 being taken generally toward an inlet portion of theair cleaner assembly.

FIG. 9 is a schematic enlarged cross-sectional view taken generallyalong line 9-9, FIG. 7A.

FIG. 9A is a schematic enlarged cross-sectional view taken in theopposite direction of the line 9-9, FIG. 7A, from the direction for theviewing of FIG. 9.

FIG. 10 is a schematic enlarged cross-sectional view of a portion ofFIG. 9.

FIG. 10A is a schematic enlarged fragmentary cross-sectional view of afirst portion of FIG. 9A.

FIG. 10B is a schematic enlarged fragmentary cross-sectional view of asecond portion of FIG. 9A.

FIG. 11 is a schematic enlarged cross-sectional view taken generallyalong line 11-11, FIG. 7A.

FIG. 12 is a schematic enlarged fragmentary cross-sectional view of aportion of FIG. 11.

FIG. 13 is a schematic side elevational view of a bottom portion of ahousing assembly useable in the air cleaner of FIG. 7; FIG. 13 is takengenerally toward a housing inlet and in FIG. 13 selected, example,dimension angle definitions are shown.

FIG. 14 is a second schematic side elevational view of the bottomportion depicted in FIG. 13.

FIG. 15 is a schematic perspective view of a filter cartridge useable inthe assembly of FIGS. 7-14; FIG. 15 being a perspective view takengenerally toward an outlet flow surface.

FIG. 16 is a schematic bottom perspective view of the cartridge depictedin FIG. 15.

FIG. 17 is a second schematic bottom perspective view of the cartridgedepicted in FIG. 15; the view of FIG. 17 being with the cartridgerotated 180° from the view of FIG. 16.

FIG. 18 is a schematic side elevational view of the cartridge depictedin FIG. 15.

FIG. 19 is a schematic side elevational view of the cartridge depictedin FIG. 15.

FIG. 20 is a schematic top plan view of the cartridge depicted in FIG.15.

FIG. 20A is a schematic cross-sectional view taken along line 20A-20A,FIG. 20.

FIG. 21 is a schematic cross-sectional view taken along line 21-21, FIG.20.

FIG. 22 is a schematic perspective view of a molded side panel componentof the cartridge depicted in FIG. 15.

FIG. 23 is a schematic side elevational view of the panel componentdepicted in FIG. 22.

FIG. 24 is a schematic cross-sectional view taken along line 24-24, FIG.23.

FIG. 24A is a schematic enlarged fragmentary view of a portion of FIG.23.

FIG. 25 is a schematic perspective view of a second molded panelcomponent useable in the cartridge of FIG. 15.

FIG. 26 is a schematic side elevational view of the molded panelcomponent of FIG. 25.

FIG. 27 is a schematic cross-sectional view taken along line 27-27, FIG.26.

FIG. 27A is a schematic enlarged fragmentary view of a portion of FIG.26.

FIG. 28 is a schematic enlarged plan view of a section of housing sealprovided in the cartridge of FIG. 15.

FIG. 29 is a schematic end elevational view of the component depicted inFIG. 28, with example dimension and angle definition indicated.

FIG. 30 is a schematic side elevational view of a first bumper componentdepicted in the cartridge of FIG. 15.

FIG. 31 is a schematic side elevational view of the component depictedin FIG. 30.

FIG. 32 is a schematic side elevational view of a second bumpercomponent useable in the cartridge of FIG. 15.

FIG. 33 is a schematic side elevational view of the component depictedin FIG. 32.

FIG. 34 is a schematic depiction of a housing seal section useable inthe cartridge of FIG. 15.

FIG. 35 is a schematic side elevational view of the component depictedin FIG. 34.

FIG. 36 is a schematic side elevational view of a bumper component useda third and fourth bumper features in the cartridge of FIG. 15.

FIG. 37 is a schematic side elevational view of the bumper componentdepicted in FIG. 36.

FIG. 38 is a schematic side elevational view in an alternate air cleanerassembly to the one depicted in FIG. 11, incorporating principlesaccording to the present disclosure.

FIG. 39 is an inlet end view of the air cleaner depicted in FIG. 38.

FIG. 40 is a top plan view of the air cleaner depicted in FIGS. 38 and39.

FIG. 41 is a cross-sectional view taken along line 41-41, FIG. 38.

FIG. 42 is an enlarged fragmentary view of a portion of FIG. 41.

FIG. 43 is a schematic top perspective view of a filter cartridgeuseable in the air cleaner of FIGS. 38-42.

FIG. 44 is a side elevational view of the filter cartridge depicted inFIG. 43.

FIG. 45 is a top plan view of the filter cartridge depicted in FIGS. 43and 44.

FIG. 46 is a cross-sectional view taken along line 46-46, FIG. 45.

FIG. 47 is a cross-sectional view taken along line 47-47, FIG. 45.

FIG. 48 is an end view of the filter cartridge depicted in FIGS. 43 and44.

FIG. 49 is a second end view, opposite FIG. 48, of the filter cartridgedepicted in FIGS. 43 and 44.

FIG. 50 is a schematic side elevational view of a molded side panelmember of the filter cartridge depicted in FIGS. 43 and 44.

FIG. 51 is a schematic perspective view of a molded seal member useablein the filter cartridge of FIGS. 43 and 44.

FIG. 52 is a top plan view of the seal member of FIG. 51.

FIG. 53 is a cross-sectional view taken along line 53-53, FIG. 52.

FIG. 54 is an enlarged fragmentary view of a portion of FIG. 53.

FIG. 55 is a cross-sectional view taken along line 55-55, FIG. 52.

Some dimension and angle lines are provided in certain drawings, withcorresponding example figures provided in the text as examples.Alternate sizes are possible.

DETAILED DESCRIPTION I. Z-Filter Media Configurations, Generally

Fluted filter media can be used to provide fluid filter constructions ina variety of manners. One well known manner is as a z-filterconstruction. The term “z-filter construction” as used herein, is meantto refer to a filter construction in which individual ones ofcorrugated, folded or otherwise formed filter flutes are used to definesets of longitudinal, typically parallel, inlet and outlet filter flutesfor fluid flow through the media; the fluid flowing along the length ofthe flutes between opposite inlet and outlet flow ends (or flow faces)of the media. Some examples of z-filter media are provided in U.S. Pat.Nos. 5,820,646; 5,772,883; 5,902,364; 5,792,247; 5,895,574; 6,210,469;6,190,432; 6,350,296; 6,179,890; 6,235,195; Des. 399,944; Des. 428,128;Des. 396,098; Des. 398,046; and, Des. 437,401; each of these fifteencited references being incorporated herein by reference.

One type of z-filter media, utilizes two specific media componentsjoined together, to form the media construction. The two components are:(1) a fluted (typically corrugated) media sheet; and, (2) a facing mediasheet. The facing media sheet is typically non-corrugated, however itcan be corrugated, for example perpendicularly to the flute direction asdescribed in U.S. provisional 60/543,804, filed Feb. 11, 2004,incorporated herein by reference.

The fluted (typically corrugated) media sheet and the facing media sheettogether, are used to define media having parallel inlet and outletflutes. In some instances, the fluted sheet and facing sheet are securedtogether and are then coiled to form a z-filter media construction. Sucharrangements are described, for example, in U.S. Pat. Nos. 6,235,195 and6,179,890, each of which is incorporated herein by reference. In certainother arrangements, some non-coiled sections of corrugated media securedto facing media are stacked on one another, to create a filterconstruction. An example of this is described in FIG. 11 of U.S. Pat.No. 5,820,646, incorporated herein by reference.

The term “corrugated” used herein to refer to structure in media, ismeant to refer to a flute structure resulting from passing the mediabetween two corrugation rollers, i.e., into a nip or bite between tworollers, each of which has surface features appropriate to cause acorrugation affect in the resulting media. The term “corrugation” is notmeant to refer to flutes that are formed by techniques not involvingpassage of media into a bite between corrugation rollers. However, theterm “corrugated” is meant to apply even if the media is furthermodified or deformed after corrugation, for example by the foldingtechniques described in PCT WO 04/007054, published Jan. 22, 2004,incorporated herein by reference.

Corrugated media is a specific form of fluted media. Fluted media ismedia which has individual flutes (for example formed by corrugating orfolding) extending thereacross.

Serviceable filter element or filter cartridge configurations utilizingz-filter media are sometimes referred to as “straight through flowconfigurations” or by variants thereof. In general, in this context whatis meant is that the serviceable filter elements generally have an inletflow end (or face) and an opposite exit flow end (or face), with flowentering and exiting the filter cartridge in generally the same straightthrough direction. The term “serviceable” in this context is meant torefer to a media containing filter cartridge that is periodicallyremoved and replaced from a corresponding fluid (e.g. air) cleaner. Insome instances, each of the inlet flow end and outlet flow end will begenerally flat or planar, with the two parallel to one another. However,variations from this, for example non-planar faces, are possible.

A straight through flow configuration (especially for a coiled mediapack) is, for example, in contrast to serviceable filter cartridges suchas cylindrical pleated filter cartridges of the type shown in U.S. Pat.No. 6,039,778, incorporated herein by reference, in which the flowgenerally makes a turn inside of the cartridge and as its passes throughthe serviceable cartridge. That is, in a U.S. Pat. No. 6,039,778 filter,the flow enters the cylindrical filter cartridge through a cylindricalside, and then turns to exit through an end face (in forward-flowsystems). In a typical reverse-flow system, the flow enters theserviceable cylindrical cartridge through an end face and then turns toexit through a side of the cylindrical filter cartridge. An example ofsuch a reverse-flow system is shown in U.S. Pat. No. 5,613,992,incorporated by reference herein.

The term “z-filter media construction” and variants thereof as usedherein, without more, is meant to refer to any or all of: a web ofcorrugated or otherwise fluted media secured to (facing) media withappropriate sealing to allow for definition of inlet and outlet flutes;and/or, a media pack constructed or formed from such media into a threedimensional network of inlet and outlet flutes; and/or, a filtercartridge or construction including such a media pack.

In FIG. 1, an example of media 1 useable in z-filter media is shown. Themedia 1 is formed from a corrugated sheet 3 and a facing sheet 4.

In general, the corrugated sheet 3, FIG. 1 is of a type generallycharacterized herein as having a regular, curved, wave pattern of flutesor corrugations 7. The term “wave pattern” in this context, is meant torefer to a flute or corrugated pattern of alternating troughs 7 b andridges 7 a. The term “regular” in this context is meant to refer to thefact that the pairs of troughs and ridges (7 b, 7 a) alternate withgenerally the same repeating corrugation (or flute) shape and size.(Also, typically in a regular configuration each trough 7 b issubstantially an inverse of each ridge 7 a.) The term “regular” is thusmeant to indicate that the corrugation (or flute) pattern comprisestroughs and ridges with each pair (comprising an adjacent trough andridge) repeating, without substantial modification in size and shape ofthe corrugations along at least 70% of the length of the flutes. Theterm “substantial” in this context, refers to a modification resultingfrom a change in the process or form used to create the corrugated orfluted sheet, as opposed to minor variations from the fact that themedia sheet 3 is flexible. With respect to the characterization of arepeating pattern, it is not meant that in any given filterconstruction, an equal number of ridges and troughs is necessarilypresent. The media 1 could be terminated, for example, between a paircomprising a ridge and a trough, or partially along a pair comprising aridge and a trough. (For example, in FIG. 1 the media 1 depicted infragmentary has eight complete ridges 7 a and seven complete troughs 7b.) Also, the opposite flute ends (ends of the troughs and ridges) mayvary from one another. Such variations in ends are disregarded in thesedefinitions, unless specifically stated. That is, variations in the endsof flutes are intended to be covered by the above definitions.

In the context of the characterization of a “curved” wave pattern ofcorrugations, the term “curved” is meant to refer to a corrugationpattern that is not the result of a folded or creased shape provided tothe media, but rather the apex 7 a of each ridge and the bottom 7 b ofeach trough is formed along a radiused curve. A typical radius for suchz-filter media would be at least 0.25 mm and typically would be not morethan 3 mm.

An additional characteristic of the particular regular, curved, wavepattern depicted in FIG. 1, for the corrugated sheet 3, is that atapproximately a midpoint 30 between each trough and each adjacent ridge,along most of the length of the flutes 7, is located a transition regionwhere the curvature inverts. For example, viewing back side or face 3 a,FIG. 1, trough 7 b is a concave region, and ridge 7 a is a convexregion. Of course when viewed toward front side or face 3 b, trough 7 bof side 3 a forms a ridge; and, ridge 7 a of face 3 a, forms a trough.(In some instances, region 30 can be a straight segment, instead of apoint, with curvature inverting at ends of the segment 30.)

A characteristic of the particular regular, curved, wave patterncorrugated sheet 3 shown in FIG. 1, is that the individual corrugationsare generally straight. By “straight” in this context, it is meant thatthrough at least 70%, typically at least 80% of the length between edges8 and 9, the ridges 7 a and troughs 7 b do not change substantially incross-section. The term “straight” in reference to corrugation patternshown in FIG. 1, in part distinguishes the pattern from the taperedflutes of corrugated media described in FIG. 1 of WO 97/40918 and PCTPublication WO 03/47722, published Jun. 12, 2003, incorporated herein byreference. The tapered flutes of FIG. 1 of WO 97/40918, for example,would be a curved wave pattern, but not a “regular” pattern, or apattern of straight flutes, as the terms are used herein.

Referring to the present FIG. 1 and as referenced above, the media 1 hasfirst and second opposite edges 8 and 9. When the media 1 is coiled andformed into a media pack, in general edge 9 will form an inlet end forthe media pack and edge 8 an outlet end, although an oppositeorientation is possible.

Adjacent edge 8 is provided a sealant bead 10, or other sealarrangement, sealing the corrugated sheet 3 and the facing sheet 4together. Bead 10 will sometimes be referred to as a “single facer”bead, since it is a bead between the corrugated sheet 3 and facing sheet4, which forms the single facer or media strip 1. Sealant bead 10 sealsclosed individual flutes 11 adjacent edge 8, to passage of airtherefrom.

Adjacent edge 9, is provided seal bead 14, or seal arrangement. Sealbead 14 generally closes flutes 15 to passage of unfiltered fluidtherein, adjacent edge 9. Bead 14 would typically be applied as stripsof the media 1 are secured to one another during stacking. Thus, bead 14will form a seal between a back side 17 of facing sheet 4, and side 18of the next adjacent corrugated sheet 3. When the media 1 is cut instrips and stacked, instead of coiled, bead 14 is sometimes referencedas a “stacking bead.” (When bead 14 is used in a coiled arrangement, notdepicted herein, it is sometimes referenced as a “winding bead.”)

Referring to FIG. 1, once the media 1 is incorporated into a media pack,for example by stacking, it can be operated as follows. First, air inthe direction of arrows 12, would enter open flutes 11 adjacent end 9.Due to the closure at end 8, by bead 10, the air would pass through themedia shown by arrows 13. It could then exit the media pack, by passagethrough open ends 15 a of the flutes 15, adjacent end 8 of the mediapack. Of course operation could be conducted with air flow in theopposite direction.

For the particular arrangement shown herein in FIG. 1, the parallelcorrugations 7 a, 7 b are generally straight completely across themedia, from edge 8 to edge 9. Straight flutes or corrugations can bedeformed or folded at selected locations, especially at ends.Modifications at flute ends for closure are generally disregarded in theabove definitions of “regular,” “curved” and “wave pattern.”

Z-filter constructions which do not utilize straight, regular curvedwave pattern corrugation shapes are known. For example in Yamada et al.U.S. Pat. No. 5,562,825 corrugation patterns which utilize somewhatsemicircular (in cross section) inlet flutes adjacent narrow V-shaped(with curved sides) exit flutes are shown (see FIGS. 1 and 3, of U.S.Pat. No. 5,562,825). In Matsumoto, et al. U.S. Pat. No. 5,049,326circular (in cross-section) or tubular flutes defined by one sheethaving half tubes attached to another sheet having half tubes, with flatregions between the resulting parallel, straight, flutes are shown, seeFIG. 2 of Matsurnoto '326. In Ishii, et al. U.S. Pat. No. 4,925,561(FIG. 1) flutes folded to have a rectangular cross section are shown, inwhich the flutes taper along their lengths. In WO 97/40918 (FIG. 1),flutes or parallel corrugations which have a curved, wave patterns (fromadjacent curved convex and concave troughs) but which taper along theirlengths (and thus are not straight) are shown. Also, in WO 97/40918flutes which have curved wave patterns, but with different sized ridgesand troughs, are shown.

In general, the filter media is a relatively flexible material,typically a non-woven fibrous material (of cellulose fibers, syntheticfibers or both) often including a resin therein, sometimes treated withadditional materials. Thus, it can be conformed or configured into thevarious corrugated patterns, without unacceptable media damage. Also, itcan be readily coiled or otherwise configured for use, again withoutunacceptable media damage. Of course, it must be of a nature such thatit will maintain the required corrugated configuration, during use.

In the corrugation process, an inelastic deformation is caused to themedia. This prevents the media from returning to its original shape.However, once the tension is released the flute or corrugations willtend to spring back, recovering at least a portion of the stretch andbending that has occurred. The facing sheet is sometimes tacked to thefluted sheet, to inhibit this spring back in the corrugated sheet.

Also, typically, the media contains a resin. During the corrugationprocess, the media can be heated to above the glass transition point ofthe resin. When the resin then cools, it will help to maintain thefluted shapes.

The media of the corrugated sheet 3 facing sheet 4 or both, can beprovided with a fine fiber material on one or both sides thereof, forexample in accord with U.S. Pat. No. 6,673,136, incorporated herein byreference.

An issue with respect to z-filter constructions relates to closing ofthe individual flute ends. Although alternatives are possible, typicallya sealant or adhesive is provided, to accomplish the closure. As isapparent from the discussion above, in typical z-filter media,especially that which uses straight flutes as opposed to tapered flutes,large sealant surface areas (and volume) at both the upstream end andthe downstream end are needed. High quality seals at these locations arecritical to proper operation of the media structure that results. Thehigh sealant volume and area, creates issues with respect to this.

Attention is now directed to FIG. 2, in which a z-filter mediaconstruction 40 utilizing a regular, curved, wave pattern corrugatedsheet 43, and a non-corrugated (flat) flowing sheet 44, is depicted. Thedistance D1, between points 50 and 51, defines the extension of media 44in region 52 underneath a given corrugated flute 53. The length D2 ofthe arcuate media for the corrugated flute 53, over the same distance D1is of course larger than D1, due to the shape of the corrugated flute53. For a typical regular shaped media used in fluted filterapplications, the linear length D2 of the media 53 between points 50 and51 will often be at least 1.2 times D1. Typically, D2 would be within arange of 1.2-2.0, inclusive. One particularly convenient arrangement forair filters has a configuration in which D2 is about 1.25-1.35×D1. Suchmedia has, for example, been used commercially in Donaldson Powercore™Z-filter arrangements. Herein the ratio D2/D1 will sometimes becharacterized as the flute/flat ratio or media draw for the corrugatedmedia.

In the corrugated cardboard industry, various standard flutes have beendefined. For example the standard E flute, standard X flute, standard Bflute, standard C flute and standard A flute. FIG. 3, attached, incombination with Table A below provides definitions of these flutes.

Donaldson Company, Inc., (DCI) the assignee of the present disclosure,has used variations of the standard A and standard B flutes, in avariety of z-filter arrangements. These flutes are also defined in TableA and FIG. 3.

TABLE A Flute definitions for FIG. 3 DCI A Flute: Flute/flat = 1.52:1;The Radii (R) are as follows: R1000 = .0675 inch (1.715 mm); R1001 =.0581 inch (1.476 mm); R1002 = .0575 inch (1.461 mm); R1003 = .0681 inch(1.730 mm); DCI B Flute: Flute/flat = 1.32:1; The Radii (R) are asfollows: R1004 = .0600 inch (1.524 mm); R1005 = .0520 inch (1.321 mm);R1006 = .0500 inch (1.270 mm); R1007 = .0620 inch (1.575 mm); Std. EFlute: Flute/flat = 1.24:1; The Radii (R) are as follows: R1008 = .0200inch (.508 mm); R1009 = .0300 inch (.762 mm); R1010 = .0100 inch (.254mm); R1011 = .0400 inch (1.016 mm); Std. X Flute: Flute/flat = 1.29:1;The Radii (R) are as follows: R1012 = .0250 inch (.635 mm); R1013 =.0150 inch (.381 mm); Std. B Flute: Flute/flat = 1.29:1; The Radii (R)are as follows: R1014 = .0410 inch (1.041 mm); R1015 = .0310 inch (.7874mm); R1016 = .0310 inch (.7874 mm); Std. C Flute: Flute/flat = 1.46:1;The Radii (R) are as follows: R1017 = .0720 inch (1.829 mm); R1018 =.0620 inch (1.575 mm); Std. A Flute: Flute/flat = 1.53:1; The Radii (R)are as follows: R1019 = .0720 inch (1.829 mm); R1020 = .0620 inch (1.575mm).

Of course other, standard, flutes definitions from the corrugated boxindustry are known.

In general, standard flute configurations from the corrugated boxindustry can be used to define corrugation shapes or approximatecorrugation shapes for corrugated media. Comparisons above between theDCI A flute and DCI B flute, and the corrugation industry standard A andstandard B flutes, indicate some convenient variations.

Referring again to FIG. 1, at 20 lines of tack beads are shown betweenfluted sheet 3 and the facing sheet 4. Adhesive is used at theselocations, to facilitate securing the two sheets. The adhesive lines donot need to be continuous.

It should be understood that air can move between adjacent inlet flutes,without passing through media. Air can also move between adjacent outletflutes, without passing through media. However, air cannot move from aninlet flute to an outlet flute, without passage through the media (withfiltering flow).

II. Manufacture of Stacked Media Configurations Using Fluted Media,Generally

In FIG. 4, one example of a manufacturing process for making a mediastrip corresponding to strip 1, FIG. 1 is shown. In general, facingsheet 64 and the fluted (in the example shown corrugated) sheet 66having flutes 68 are brought together to form a media web 69, with anadhesive bead located therebetween at 70. The adhesive bead 70 will forma single facer bead 10, FIG. 1. An optional darting process occurs atstation 71 to form center darted section 72 located mid-web. Thez-filter media or Z-media strip 74 can be cut or slit at 75 along thebead 70 to create two pieces 76, 77 of z-filter media 74, each of whichhas an edge with a strip of sealant (single facer bead) extendingbetween the corrugating and facing sheet. Of course, if the optionaldarting process is used, the edge with a strip of sealant (single facerbead) would also have a set of flutes darted at this location. Thestrips or pieces 76, 77 can then be cut across, for stacking, asdescribed below in connection with FIG. 6.

Techniques for conducting a process as characterized with respect toFIG. 4 are described in PCT WO 04/007054, published Jan. 22, 2004incorporated herein by reference.

Still in reference to FIG. 4, before the z-filter media 74 is putthrough the darting station 71 the media 74 must be formed. In theschematic shown in FIG. 4, this is done by passing a flat sheet of media92 through a pair of corrugation rollers 94, 95. In the schematic shownin FIG. 4, the flat sheet of media 92 is unrolled from a roll 96, woundaround tension rollers 98, and then passed through a nip or bite 102between the corrugation rollers 94, 95. The corrugation rollers 94, 95have teeth 104 that will give the general desired shape of thecorrugations after the flat sheet 92 passes through the nip 102. Afterpassing through the nip 102, the flat sheet 92 becomes corrugated and isreferenced at 66 as the corrugated sheet. The corrugated sheet 66 isthen secured to facing sheet 64. (The corrugation process may involveheating the media, in some instances.)

Still in reference to FIG. 4, the process also shows the facing sheet 64being routed to the darting process station 71. The facing sheet 64 isdepicted as being stored on a roll 106 and then directed to thecorrugated sheet 66 to form the Z-media 74. The corrugated sheet 66 andthe facing sheet 64 are secured together by adhesive or by other means(for example by sonic welding).

Referring to FIG. 4, an adhesive line 70 is shown used to securecorrugated sheet 66 and facing sheet 64 together, as the sealant bead.Alternatively, the sealant bead for forming the facing bead could beapplied as shown as 70 a. If the sealant is applied at 70 a, it may bedesirable to put a gap in the corrugation roller 95, and possibly inboth corrugation rollers 94, 95, to accommodate the bead 70 a.

Of course equipment can be added to the assembly line, to apply the tackbeads 20, FIG. 1, if used.

The type of corrugation provided to the corrugated media is a matter ofchoice, and will be dictated by the corrugation or corrugation teeth ofthe corrugation rollers 94, 95. One preferred corrugation pattern willbe a regular curved wave pattern corrugation, of straight flutes, asdefined herein above. A typical regular curved wave pattern used, wouldbe one in which the distance D2, as defined above, in a corrugatedpattern is at least 1.2 times the distance D1 as defined above. In onepreferred application, typically D2=1.25−1.35×D1. In some instances thetechniques may be applied with curved wave patterns that are not“regular,” including, for example, ones that do not use straight flutes.

As described, the process shown in FIG. 4 can be used to create thecenter darted section 72. FIG. 5 shows, in cross-section, one of theflutes 68 after darting and slitting.

A fold arrangement 118 can be seen to form a darted flute 120 with fourcreases 121 a, 121 b, 121 c, 121 d. The fold arrangement 118 includes aflat first layer or portion 122 that is secured to the facing sheet 64.A second layer or portion 124 is shown pressed against the first layeror portion 122. The second layer or portion 124 is preferably formedfrom folding opposite outer ends 126, 127 of the first layer or portion122.

Still referring to FIG. 5, two of the folds or creases 121 a, 121 b willgenerally be referred to herein as “upper, inwardly directed” folds orcreases. The term “upper” in this context is meant to indicate that thecreases lie on an upper portion of the entire fold 120, when the fold120 is viewed in the orientation of FIG. 5. The term “inwardly directed”is meant to refer to the fact that the fold line or crease line of eachcrease 121 a, 121 b, is directed toward the other.

In FIG. 5, creases 121 c, 121 d, will generally be referred to herein as“lower, outwardly directed” creases. The term “lower” in this contextrefers to the fact that the creases 121 c, 121 d are not located on thetop as are creases 121 a, 121 b, in the orientation of FIG. 5. The term“outwardly directed” is meant to indicate that the fold lines of thecreases 121 c, 121 d are directed away from one another.

The terms “upper” and “lower” as used in this context are meantspecifically to refer to the fold 120, when viewed from the orientationof FIG. 5. That is, they are not meant to be otherwise indicative ofdirection when the fold 120 is oriented in an actual product for use.

Based upon these characterizations and review of FIG. 5, it can be seenthat a preferred regular fold arrangement 118 according to FIG. 5 inthis disclosure is one which includes at least two “upper, inwardlydirected, creases.” These inwardly directed creases are unique and helpprovide an overall arrangement in which the folding does not cause asignificant encroachment on adjacent flutes.

A third layer or portion 128 can also be seen pressed against the secondlayer or portion 124. The third layer or portion 128 is formed byfolding from opposite inner ends 130, 131 of the third layer 128.

Another way of viewing the fold arrangement 118 is in reference to thegeometry of alternating ridges and troughs of the corrugated sheet 66.The first layer or portion 122 is formed from an inverted ridge. Thesecond layer or portion 124 corresponds to a double peak (afterinverting the ridge) that is folded toward, and in preferredarrangements, folded against the inverted ridge.

Techniques for providing the optional dart described in connection withFIG. 5, in a preferred manner, are described in PCT WO 04/007054,incorporated herein by reference. Other techniques for media managementare described in PCT application US 04/07927, filed Mar. 17, 2004,incorporated herein by reference.

Techniques described herein are well adapted for use of media packs thatresult from arrangements that, instead of being formed by coiling, areformed from a plurality of strips of single facer.

Opposite flow ends or flow faces of the media pack can be provided witha variety of different definitions. In many arrangements, the ends aregenerally flat and perpendicular to one another.

The flute seals (single facer bead, winding bead or stacking bead) canbe formed from a variety of materials. In various ones of the cited andincorporated references, hot melt or polyurethane seals are described aspossible for various applications. These are useable for applicationsdescribed herein.

In FIG. 6, schematically there is shown a step of forming a stackedz-filter media pack from strips of z-filter media. Referring to FIG. 6,strip 200 is being shown added to a stack 201 of strips 202 analogous tostrip 200. Strip 200 can be cut from either of strips 76, 77, FIG. 4. At205, FIG. 6, application of a stacking bead 206 is shown, between eachlayer corresponding to a strip 200, 202 at an opposite edge from thesingle facer bead or seal. In FIG. 6, each layer is added to a top ofthe stack. Such layers could alternatively be added to the bottom.

Also, in some alternate processing approaches sealant bead 206 can beadded to the underside (i.e., facing sheet side) of each strip, asopposed to the fluted sheet (corrugated) side of each single facerstrip.

Referring to FIG. 6, each strip 200, 202 has front and rear edges 207,208 and opposite side edges 209 a, 209 b. Inlet and outlet flutes of thecorrugated sheet/facing sheet combination comprising each strip 200, 202generally extend between the front and rear edges 207, 208, and parallelto side edges 209 a, 209 b. Sides 209 a, 209 b are sometimes referencedas tail and lead ends of the media strips 200.

Still referring to FIG. 6, in the media pack 201 being formed, oppositeflow faces are indicated at 210, 211. The selection of which one offaces 210, 211 is the inlet end face and which is the outlet end face,during filtering, is a matter of choice. In some instances the stackingbead 206 is preferably positioned adjacent the upstream or inlet face211. The flow faces 210, 211, extend between opposite side faces 220,221.

The stacked media pack 201 being formed in FIG. 6, is sometimes referredto herein as a “blocked” stacked media pack. The term “blocked” in thiscontext, is an indication that the arrangement is formed to arectangular block in which all faces are at or nearly at 900 relative toall adjoining wall faces. Alternate configurations are possible, asdiscussed in U.S. Provisional application 60/579,754, filed Jun. 14,2004, incorporated herein by reference. One example of an alternateconfiguration, would be one in which instead of each cross-section ofthe stacked media pack arrangement having rectangular (or rightquadrilateral) cross-section, at least one of the cross-sections is aoblique parallelogram cross-section. In such a parallelogram, oppositesides are parallel to one another, but adjacent sides do not meet at aright angle, but rather meet at a defined angle other than 90°. Certainof the techniques described herein below can be used with either ablocked or a slanted stacked arrangement. In the figures, a blockedarrangement is shown.

Still other stacked shapes are possible, depending on how the individualsheets, in forming the stack, are positioned relative to adjacentsheets.

In some instances, the media pack 201 shown will be referenced as havinga parallelogram shape in any cross-section, meaning that any twoopposite side faces extend generally parallel to one another.

It is noted that a blocked, stacked arrangement corresponding to FIG. 6is described in the prior art of U.S. Pat. No. 5,820,646, incorporatedherein by reference. It is also noted that stacked arrangements aredescribed in U.S. Pat. Nos. 5,772,883; 5,792,247; U.S. Provisional60/457,255 filed Mar. 25, 2003; and U.S. Ser. No. 10/731,564 filed Dec.8, 2003. All four of these latter references are incorporated herein byreference. It is noted that the stacked arrangement at FIG. 6 of U.S.Ser. No. 10/731,504, is a slanted or oblique parallelogram stackedarrangement.

Of course the methods disclosed are merely examples. Useable z-filtermedia packs can be formed in alternate manners.

III. An Air Cleaner Assembly, FIGS. 7-14

In FIGS. 7-14, an air cleaner assembly is shown, which utilizesprinciples according to the present disclosure. The assembly depicted ismeant to show an example embodiment for applications to the principles.The principles can be applied in a variety of alternate arrangements. InFIGS. 15-21, filter cartridge useable in the assembly of FIGS. 7-14 isdepicted. The cartridge of FIGS. 15-21, is discussed in Section IVbelow.

In FIGS. 22-37 features of the cartridge depicted in FIGS. 15-21, arealso shown. These are also discussed in Section IV below.

It is noted that for an assembly to be improved according to theprinciples of the present disclosure, it is not required that theassembly include all of the features illustrated in the depictedexamples and described herein.

Air cleaner assemblies of the types depicted in FIGS. 7-14, aregenerally meant to be used within an enclosed engine compartment of avehicle, such as a truck. Examples would be a pickup truck or a sportsutility vehicle (SUV), or other vehicle. Of course the principles can beapplied with air cleaners that are mounted elsewhere, however theprinciples described are particularly applied for assemblies which areconfigured to be positioned where there is limited space for equipmentmounting, and service access.

The reference numeral 300, FIG. 7, generally indicates an air cleanerassembly embodying principles according to the present disclosure. Theair cleaner assembly 300 comprises a housing 302, a dirty air inlet ductarrangement 303 and a clean air outlet duct arrangement 304.

In general, housing 302 comprises housing base or bottom portion 307 andtop or access cover 308. Cover 308 is removably secured to bottom 307,in this instance by latches 310. For the particular assembly 300 shown,there are four such latches 310 provided in two pairs, along selectedopposite sides 302 a, 302 b of the housing 302. This can be seen byreference to FIG. 7A, in which an opposite side 302 b from that (302 a)viewable in FIG. 7 is shown.

It is noted that for the assembly 300 of FIG. 7 and FIG. 7A, a pair ofopposite sides 302 c, 302 d are provided which have no latches thereon.

Air cleaner assembly 300 would typically be mounted in the generalorientation shown in FIGS. 7 and 7A, with cover 308 positioned abovebase 307. Service access to an interior 309, of housing 302, FIG. 9,would generally be obtained from above, by removal of access cover 308.This facilitates servicing of interiorly received componentry, asdescribed below.

Cover 308 includes a peripheral, perimeter, flange arrangement 312oriented to engage a peripheral perimeter flange arrangement 313 on base307, when housing 302 is assembled. As will be understood from furtherdescriptions below, peripheral perimeter flange arrangement 312 isgenerally oriented in overlap with peripheral perimeter flangearrangement 313, with a housing seal arrangement of an interiorlyreceived filter cartridge, positioned and sealed therebetween. This willbe understood from further discussions below in connection with otherfigures.

In general operation, dirty air to be filtered will be directed intohousing 302 through inlet duct arrangement 303, FIG. 7. It is noted thatthe inlet duct 303 for the assembly shown, is directed into a lowerportion 315 of base 307. The air would then pass upwardly through aninternally received filter cartridge 330, FIG. 9, by which it would befiltered. The air would then pass into clean air outlet duct arrangement304. Referring to FIG. 7, it is noted that clean air outlet duct 304engages cover 308, generally in both a central upper portion 316 and acorner portion 316 a thereof.

It will be apparent then that when the assembly 300 is mounted in avehicle or other equipment in the orientation shown in FIG. 7, thedirection of filtering flow through an interior of housing 302, isgenerally upwardly.

Referring to FIGS. 7 and 7A, housing 302 includes mounting posts 320secured to bottom portion 307. The assembly 300 can be operably(secured) mounted in a vehicle or onto other equipment, by posts 320,typically with bolts 320 a providing attachment. The posts 320 would besized, positioned and directed as appropriate, for a specificinstallation.

In a typical application, base 307 can be molded, integrally, from astructurally rigid plastic material. Cover or top 308 could also bemolded, integrally, from a similar or identical plastic material. Ribstructures 321, FIGS. 7 and 7A can be provided in the molded plasticcomponents, to provide structural rigidity. It is noted that a varietyof structural materials could be used; and, that many of the techniquesdescribed herein can be applied in arrangements that are not molded.

Still referring to FIG. 7, for assembly 300 depicted, the outlet ductarrangement 304 includes a conduit 325, secured to the housing 302. Theconduit 325 can be used to direct the cleaned air into a manifoldassembly 326 and into engine componentry, where the air is used.Typically the air would be directed to an engine combustion air intakeor into a turbo charger or similar system.

Attention is now directed to FIG. 9, in which assembly 300 is depictedin cross-sectional view, taken generally along line 9-9, FIG. 7. In FIG.9, housing interior 309 is viewable. Operably received within interior302 is positioned filter cartridge 330. The filter cartridge 330 is aserviceable filter cartridge, meaning that the cartridge 330 isconfigured so that it can be removed and replaced, within interior 309.A typical service operation comprises removing cover 308 from base 307,by unlatching latches 310, and then removing cartridge 330 and replacingit with a refurbished or new cartridge. The cartridge 330 depicted,comprises cartridge 400 described below in connection with FIGS. 15-37.

Still referring to FIG. 9, outlet conduit section 332 is viewable. Itcan be seen that a portion of the conduit 332 is opened into interior302, through a top central portion 316 of cover 308, and another portionenters interior 302 through corner section 316 a.

Attention is now directed to FIG. 9A, which is a cross-section analogousto FIG. 9, but taken facing the opposite direction. Here the entryjuncture 303 a between inlet conduit arrangement 303 and base 307 isviewable. It can be seen that the entry generally occurs underneathcartridge 330; or, more generally, along an opposite side of cartridge330 from outlet arrangement 304.

Attention is now directed to FIG. 10. In FIG. 10 a fragmentarycross-sectional view of a portion of FIG. 9 is depicted, the portiongenerally comprising a selected location where peripheral perimeterflange 312 on cover 308 overlaps peripheral perimeter flange arrangement313 on base 307.

Referring to FIG. 10, cartridge 330 is shown having a peripheral,perimeter, housing seal member 340 thereon. Housing seal member 340generally extends peripherally around media pack 341 of cartridge 330.Detail concerning the construction of cartridge 330 is provided hereinbelow, in connection with FIGS. 15-37.

Housing seal member 340 is generally a compressible member, for examplea compressible polymeric material. Examples are described below.

Referring to FIG. 10, peripheral flange arrangement 312 comprises:outwardly projecting flange 345; outer peripheral lip 346 and seal edgeprojection 347.

Similarly, peripheral perimeter flange assembly 313 comprises outwardlyprojecting flange 350; sealing projecting lip 351; and, seal edgeprojection 352.

For the arrangement shown, lip 346 is sized and positioned to extendaround lip 351. Lip 351 is sized and configured to bottom out againstoutwardly projecting flange 345, when cover 308 is secured to base 307by latches 310.

In more general terms: the flanges 312, 313 include an engagementarrangement, whereby one engages the other, during preferred securing ofthe cover 308 on the base 307. A specific example is shown, in which lip351 on base 307 is sized and configured to engage flange 345 on cover308. However alternate configurations are possible, for example in whicha lip on cover 308 engages a flange on base 307.

Seal edge projection 347 is sized and positioned to press intoperipheral, perimeter, housing seal member 340, when cover 308 ismounted on base 307. Similarly, seal edge projection 352 is sized andpositioned to press into housing seal member 340, when cover 308 ispositioned on base 307.

It is noted that seal edge projection 347 and seal edge projection 352are radially offset from one another. That is, they are not positionedin direct overlap with one another. Referring to FIG. 10, the offset isindicated generally by dimension AA. A typical offset would be at least3 mm and often at least 4.5 mm, for example 5 to 7 mm.

In typical preferred arrangements, in which the clean air side of thecartridge 330 is provided in the cover 307, the seal edge projection 347will be positioned radially interiorly of the seal edge projection 352to advantage. Alternately stated, typically the seal edge projection 352of the air inlet portion (dirty air side) of the housing 302, in thisinstance base 307 will circumscribe a larger peripheral area of sealedge projection 347 of the air outlet portion (clean air side) of thehousing 302, in this instance at the cover 308. An advantage of this isthat the seal edge projection 347 on the clean air side of housing sealmember 340, is positioned closer to the media pack 330. This helpsensure a good seal.

Referring to FIG. 10, it is noted that the figure is schematic. Actualcompression of the peripheral, perimeter, housing seal member 340 is notshown. Rather what is shown, is the amount of interference betweenprojections 347, 352, and the undistorted side shape of the peripheralperimeter housing seal member 340. In an actual installation,projections 347, 352, would project into member 340, and distort theshape of member 340.

Typically each one of the projections 347, 352 extends in a member 340at least 0.5 mm, typically at least 1 mm, and usually within the rangeof 2-5 mm. The material of housing seal member 340 should be chosen, toallow for this projection. Typically projection 347 extends deeper intomaterial 340, than does projection 352, as shown in the drawings.Typically the amount of greater extension is at least 0.25 mm, typicallyat least 0.5 mm.

It is noted that for a typical arrangement, projection 347 does notextend more than 50% through the thickness of housing seal member 340 atthe location where it projects. Typically the amount of extension is nomore than 40% of this thickness.

Similarly, projection 352 typically extends no more than 50% through thethickness of the housing seal arrangement 340 where located. Typicallyit extends no more than 40% of this distance.

Typically and preferably each of projections 347, 352 extends at least10% of the way through the thickness of region 340, where located.Preferably in each case the extension is at least 15% of the thickness.

Preferably each projection 347, 352 comprises a knife end whichcompresses the media where at it is located at least 20%, typically 25%.

Still referring to FIG. 10, it is noted that for the assembly shown,flange 345 is positioned spaced from flange 350, when lip 351 isbottomed out against flange 345, a distance which is slightly less thana free-standing thickness of the housing seal member 340 at thislocation, as shown schematically by overlap between housing seal member340, and flanges 345, 350. Thus, an additional sealing affect beyond theprojections 347, 352, is accomplished through a general compressing ofthe housing seal member 340. For the example shown, this compressionalone (in the absence of projections 347, 352) is generally at least 5%,typically about 10%.

In FIG. 10A, analogous features of the cartridge 330 and peripheralperimeter flange arrangements 312, 313, are shown, from an oppositedirection.

In FIG. 10B, analogous features are shown on an opposite side of thehousing 302. It will be understood that such features generally extendperipherally, completely around the cartridge 330 and housing 302.

This peripheral extension is confirmed by FIG. 11, which shows across-sectional view orthogonal to the views of FIGS. 9 and 9A, andsimilar features are depicted. In FIG. 12, an enlargement is shownfurther confirming this.

In FIGS. 13 and 14, two side views of base portion 307 are shown.Example dimensions for an example assembly, are depicted forconvenience. Example dimensions would be as follows:

BB=5° (typically at least 2°, usually at least 3° and often 3°-10°,typically not more than 45° although alternatives are possible); CC=28.9mm; DD=57.9 mm; EE=49.9 mm R; FF=105.1 mm; GG=30.6 mm R; HH=35.5 mm R;II=274.7 mm; JJ=104.4 mm; KK=26.0 mm R; LL=79.6 mm; MM (FIG. 14)=322.3mm.

Of course other example dimensions can be determined as appropriate.Further, alternate dimensions could be used in alternate applications ofthe present techniques.

Attention is now directed to a comparison of FIGS. 7-14, with respect tothe definition of the housing features defined where compression of thehousing seal gasket on the cartridge will occur. In particular, it canbe seen that the locations in the housing 302 in which the sealingbetween cover 308 and base 307 occur, extend along four sides orsections 355, 356, 357 and 358, FIGS. 7 and 7A. Sections 355 and 356 canbe viewed as a first pair of oppositely positioned extension sections.Sections 357, 358 can be viewed as a second pair of opposite sections orextensions.

It is noted the seal plane defined by sections 355-358, does not extendparallel to a plane orthogonal to a central flow axis 365, FIGS. 9 and9A, extending through the air cleaner housing 302. Rather sections355-358 define a plane extending at a non-orthogonal angle to flow axis365.

Herein, the term “central flow axis” is merely meant to refer to adirection of air flow generally between the opposite media packsurfaces, during normal use. Such a central flow axis is axis 365, wouldtypically extend perpendicularly to the opposite flow surfaces,described below, of an internally received filter cartridge 330.

This non-orthogonal angle, as defined herein, results in a declinationangle BB, FIG. 13. Angle BB is defined by the first pair of extensionsor sections 355, 356, relative to a plane perpendicular to axis 365,FIG. 9. It is noted that the second pair of extensions or sections 357,358, do not extend in extension across the housing 302, for the exampleshown, at a declination angle with respect to such a plane, see forexample FIG. 14.

IV. A Filter Cartridge Useable in the Previously Described Assembly;FIGS. 15-21

Attention is directed to FIG. 15 which discloses, schematically, afilter cartridge 400 utilizing a stacked, blocked, media pack 401according to the above general description. Cartridge 400 can beutilized as cartridge 330, FIG. 9.

Referring to FIG. 15, at 400 the filter cartridge is depicted comprisinga blocked stacked (rectangular or right (normal) parallelogram) mediapack 401. To seal opposite ends of the media pack 401, are positionedside panels 402, 403. These panels can be made using the generaltechniques described in U.S. provisional application 60/579,754, filedJun. 14, 2004 and U.S. provisional application 60/616,364, filed Oct. 5,2004, modified to accomplish specific detail as described.

Referring to FIG. 6, each single facer strip 200 (comprising a sectionof corrugated sheet and facing sheet secured together) has a lead edge209 b and a tail edge 209 a. These edges result from cutting acontinuous strip of single facer into the individual sheets used to formthe media pack stack. The lead end and tail ends need to be sealedclosed. For the arrangement of FIG. 15, this sealing is conducted byside panels 402, 403.

Although alternatives are possible, in typical arrangements, asdescribed below, panels 402, 403 will be molded directly to the mediapack, to seal the lead and tail ends of the strips of single facer,within the media pack. By “molded directly to” in this context, it ismeant that there is no preform in the side panel, rather the side panelis formed in place on and joined to the media pack. This woulddistinguish, for example, a preform molded side piece which is attachedto the media pack by a potting material.

The media pack 401 has opposite flow faces 405, 406. In use, air flowsthrough the media pack 401 into one of the flow faces 405, 406 andoutwardly from the other one of flow faces 406, 405. The direction offlow is a matter of choice for the system of use. For the air cleanerassembly 300, the media pack 401 would typically be positioned with flowface 405 as the outlet flow face and flow face 406 as the inlet flowface.

It is noted that no flow path between faces 405, 406 in the media pack401 is provided that does not also require the air to pass through mediaof the media pack 401 and thus to be filtered.

A peripheral, perimeter, housing seal ring 410 is positioned in thecartridge 400. The particular seal ring 410 depicted, is an axial pinchseal ring. Herein, seal ring 410 is typically referred to as a housingseal arrangement, since it is a seal member positioned on the filtercartridge 400 at a location desirable for forming a seal between thecartridge 400 and housing components, when the filter cartridge 400 ispositioned in the air cleaner assembly 300 for use. The particularperipheral perimeter seal ring 410 depicted, extends around the panels402, 403.

Herein the term “peripheral” in reference to the housing seal ring orseal arrangement, is meant to refer to an extension 410 thatcircumscribes the media pack 401. The term “perimeter” in this contextis meant to refer to a housing seal arrangement 410 that also definesthe outer perimeter of the cartridge 400.

The filter cartridge 400 of FIG. 15 can be made by: (a) providing themedia pack 401; and, (b) molding panels 402, 403 thereto with segments410 a, 410 b of seal ring 410 thereon in separate molding operations,and then molding segments 410 a, 410 d in two separate moldingapertures. Thus, a four shot molding operation could be used. Alternatemethods of assembly are possible.

When the cartridge has the construction shown in FIGS. 15-21, oppositemedia pack sides or side surfaces 412 and 413 are exposed. For theparticular arrangement shown, media pack surface 412 would be a singlefacer surface, resulting from an exposed facing surface of a facingsheet for example at the bottom of a stack; and, surface 413 would be acorrugated surface (or fluted surface), for example at the top of amedia pack stack. The single facer sheet 412 could be a non-corrugatedsheet, or a sheet corrugated perpendicularly to the direction of thecorrugation flutes, as referenced above.

If desired, a protective sheet or panel could be provided over the mediapack surfaces 412, 413. Such protective sheets or panels could be formedfrom a variety of materials such as cardboard, plastic sheets, etc. Suchpanels can be secured in place by being placed against the media pack401 when the panels 402, 403 are molded.

In a typical cartridge 400 as shown, surface 412 and an opposite surface413 of the media pack 401, are each at least 30%, typically at least 40%exposed, i.e., uncovered of molded material. Some molded material ispositioned there over, in association with the housing seal 410 andother structure discussed below. In addition, portions of the oppositemolded panels 402, 403 may extend partially over the sides 412, 413.However, in general and in preferred arrangements, one pair of surfacescorresponding to surface 412 and an opposite surface 413, in the mediapack 401, will be at least 30%, typically at least 40% uncovered bymolded material directly molded to the media pack 401. By “directlymolded to” in this context and other context herein, it is meant thatthe portion defined is formed in a molding operation having theidentified portion of the media pack in the mold and with the resin atleast partially bonded directly to the media pack. Thus, again, apreformed end piece to which the media pack is secured by potting, isnot an end piece directly molded to the media pack.

As explained, in some instances surfaces 412 (and the correspondingopposite surface 413) can be covered by a preformed piece such as acardboard or plastic section embedded within end pieces 402, 403 and ifdesired partially within housing seal arrangement 410, securing theprotective cover in place. Such a cover would not correspond to material“molded directly to” the media pack, in accord with the abovedefinitions.

Referring to FIG. 15, cartridge 400 is particularly configured withmolded panels 402, 403 having opposite end edges 416, 417; and adjacentflow surfaces 405, 406 respectively. Portions of one or more of theseend edges 416, 417 can be configured to engage housing pieces, whenpinch seal 410 is sealed between housing pieces 308, 307. In theassembly cross-section of FIGS. 9 and 9A, engagement between a portion415 of the housing base 307 and portions of edges 417 is shown in 416.In the cross-section of FIG. 11, such engagement is shown for each ofpanels 402, 403.

It is noted that for the particular assembly 300 depicted, no engagementbetween the housing 302 and edges 416 is shown, although such anengagement could be provided.

As a result of the support by abutment between edges 417 and the housingbase 307, the media pack 401 is not merely suspended within the housing302 by the seal 410, rather it is also supported in place by thedescribed abutment. Surfaces 416, 417 can be irregular, i.e., have bumpsand indents, due to mold stand-offs. This is shown in the figures.

Herein, surfaces such as surfaces 417 which form abutment (non-sealing)surfaces for support with a housing, in use, will sometimes be referredto as “axial abutment surfaces,” the term axial in this contextreferring to abutment with engagement being in a direction parallel to adirection of air flow through the media pack 401, between surfaces 406,405.

As indicated above, a “axial abutment surface” may sometimes be formedwith a plurality of bumps and also a plurality of recesses (oralternatively stated projections and recesses) thereon.

A variety of materials can be utilized for the molded panels 402, 403and seal arrangement 410. Materials such as those described in U.S.Provisional application 60/579,754, filed Jun. 14, 2004, incorporatedherein by reference, can be used. Typical such materials arepolyurethanes, typically foamed polyurethanes. Although alternatives arepossible polyurethanes having an as-molded density of no greater thanabout 30 lbs./cu.ft. (0.48 g/cc), typically no greater than about 22lbs/cu.ft. (0.35 g/cc), and usually within the range of about 10-22lbs./cu.ft. (0.16-0.35 g/cc), are typical. Materials having a hardness,Shore A, of no greater than 30, and typically no greater than 20, oftenwithin the range of 12-20, sometimes 10-20 are typical. Harder materialscan be used, in some applications. The same material can be used, insome instances, for all molded components on cartridge 400.

The cartridge 400 is generally depicted in FIGS. 15-21 as follows. FIG.15, as explained above, is a top perspective view, with the generaldirection being toward outlet flow surface 405, and sides 402, 412.

FIG. 16 is a bottom plan view toward sides 402, 413 and inlet flow face406. FIG. 17 is similar to FIG. 16, but with the cartridge 400 rotated180° around a central axially extending axis. Thus the view is towardinlet face 406 and sides 412, 403.

FIG. 18 is a side elevational view taken generally toward side 412, FIG.15. FIG. 19 is a side elevational view generally toward side 403, FIG.15.

FIG. 20 is a top plan view taken toward side 5, FIG. 15.

FIG. 20A is a cross-sectional view taken along line 20A-20A, FIG. 20;and FIG. 21 is a cross-sectional view taken along line 21-21, FIG. 20.

FIGS. 15-21, in total, show the various externally viewable features ofthe cartridge 400. It is noted that FIGS. 15-21 are schematic, and thatspecific media features are not viewable. For example media flutes endsin surfaces 405, 406 and the seals therein are not shown. Also surfacedetail and exposed surfaces 412, 413 are not shown. As explained above,typically surface 412 would be a surface of a facing sheet, which may beflat or corrugations extending generally in a direction between sidepanels 402, 403. Surface 413, on the other hand, would typically be anexposed surface of a fluted sheet, thus it would have corrugationsextending in a direction between the faces 405, 406.

By comparison of FIGS. 15-21, it can be seen that the particularcartridge 400 depicted includes a housing seal ring 410 that does notextend in a plane parallel to flow surfaces 405, 406.

Referring to FIGS. 15-21, the housing seal ring 410 can be viewed ascomprising: a first pair 419 of opposite extensions 420, 421; and asecond pair 424 of opposite extensions 425, 426. The first pair 419 ispositioned on the side panels 402, 403, although an alternativeconstruction is possible as discussed below. The second pair 424 ispositioned on the opposite surfaces 412, 413, respectively although analternate construction is possible, as discussed below.

Although alternatives are possible, the extensions 420, 421 of the firstpair 419 are generally positioned as mirror images of one another andeach extends at an angle X to the plane of the media pack inlet andoutlet faces 406, 405 respectively. For a typical construction, angle Xwill be at least 2°, typically at least 3°. The angle X will typicallynot be larger than 45°. For the example shown the angle X is within therange of about 3°-10°. The specific example shown is about 5°.

In contrast, and although alternatives are possible, each extension 425,426 of the second pair of extensions 424, extends generally along a lineparallel to edges 406 a, 405 a of the media pack 401.

For the particular cartridge 400 depicted in FIGS. 15-21, and based upona comparison of these figures, it will be apparent that, althoughalternatives are possible, for the particular, specific, example shown,the housing seal ring 410 rests in a single plane. As a result,projection of the seal ring 410, beyond media pack surfaces 412, 413, isin a seal plane defined by angle X. Thus, the acute angle of a plane ofextension of the seal 410 beyond surfaces 412, 413, see FIG. 19, isgenerally 90°-X.

Herein, the terms “plane of extension,” “seal plane” or variants thereofin reference to a seal or seal section, is generally meant to refer to aplane defined by a line extending outwardly from the media pack 401,along a center of the seal and in the longitudinal direction of theseal, for example as shown in FIG. 19, at 427. It is noted that the sealarrangement 410 is shown in a not completely rectangular cross-section,but rather with a somewhat trapezoidal shape, to provide a draft anglefor demolding. This is disregarded with respect to the defined angles.

In general, advantages result from a construction in which the housingring 410 does not extend simply in a plane parallel to the flow faces405, 406. These advantages relate to at least two general observationsas follows:

-   -   1. Desirable accessibility for element and related desirable        configuration for housing; and    -   2. Improvement and control of internal ballooning of media pack        401.        A. Improvement In Accessibility of Filter Cartridge 400.

Attention is now directed to FIG. 13. In FIG. 13 the housing base 307 isshown in side view. A portion 355 of outwardly projecting flange 350 isshown. It can be understood that when the cartridge 400, FIG. 15 ispositioned with housing seal ring 410 in engagement with flange 350, aportion indicated at corner 430, FIG. 15 of the cartridge 400 willproject outwardly from housing base 407. This will provide a convenientprojection for service personnel to grasp and lift cartridge 401 out ofhousing base 407, once cover 408 has been removed.

B. Inhibition of Ballooning.

In general, air entering the media pack 401 at inlet surface 406 willcause an internal pressure build-up within the media pack 401. This willtend to balloon the media pack 401 outwardly. Such ballooning can beginto separate individual layers of media, within the media pack 401, andcause damage.

The peripheral housing seal gasket or ring 410, generally surrounds themedia pack 401 and helps control ballooning in the area where thehousing seal ring 410 is located, especially when supported within thehousing 302. However, ballooning tends to occur at least in regionsupstream (toward the dirty air side) of where the housing sealarrangement is located, in some arrangements. By providing the gasket410 with extensions that are non-parallel to an end surface, and notadjacent an end surface, such as the first pair of extensions 419,improved support against ballooning is provided.

In more general terms, ballooning is inhibit by a gasket or ring 410that is not simply in a plane parallel to surfaces 405, 406. Rather itis facilitated by having ring 410 positioned so that one portion of thering 410 is closer to surface 405 and another portion of the ring 410.This provides for some axial extension of the ring 410 between the faces405, 406 and greater inhibition to ballooning. In general the greaterthe angle X, the greater inhibition of ballooning.

From a review of FIGS. 15-21, an additional feature of the cartridge 400is understandable. In particular, cartridge 400 includes a plurality ofnon-sealing cushions or bumper features 435. Referring to FIGS. 15, 16and 17, first pair of extensions 435, comprising extensions 435 a and435 b, extend across one of the sides 412. A second pair of extensions435 comprising extensions 435 c and 435 d, FIG. 16, extend across asecond side, in this instance a side 413. For the particular exampleshown, the cushions 435 a-435 d, extend across the sides 412, 413,between moldings 402, 403.

As indicated, cushioning or bumper features 435 are generallynon-sealing. They are positioned to provide for ensuring spacing betweenthe media pack 401 and a housing side wall, when cartridge 400 isassembled in air cleaner 300 for use. They can be specifically providedof a size to engage a housing side wall, or a space between them and theside wall can be left. Preferably the cushioning or bumper features 435are manufactured from a similar material to the panels 402, 403 and theseal arrangement 400.

For the particular example shown, each of the cushioning arrangements orbumper members 435 a-435 d, extends in a direction generally parallel toedges between the associated side and the flow surfaces 405, 406.

Referring to FIG. 15, for the particular cartridge 400 depicted, housingseal arrangement 410 is positioned spaced between, not adjacent to,either one of sides 405, 406. Alternate arrangements are possible,including ones in which a portion of housing seal arrangement 410projects outwardly from a side, for example side 412, at a locationadjacent an edge between that side (side 412) and one of the flow pieces(405, 406). This can be advantageous, is some systems, depending on themethod used for assembling the cartridge 400.

V. Example Methods of Cartridge Manufacture

In this section, molding steps usable to form the cartridge FIGS. 15-21are generally described. It is known that alternate methods ofmanufacture can be used, the steps and descriptions merely indicate anexample.

In FIG. 22 a molded construction 500 is shown, which would correspond topanel 402 and seal section or extension 420, FIG. 15. It is noted thatin FIG. 22, molded arrangement 500 is shown inverted relative to theview point of FIG. 15. Although alternatives are possible, panelarrangement 402 and seal extension 420 can be molded together,simultaneously, on an appropriate portion of a media pack 401.

In FIG. 23, side elevational view of molded panel arrangement 500 isdepicted. Example dimensions usable to form a cartridge 400 that itselfis usable within assembly 300 as characterized herein are provided asfollows: NN=132.1 mm; and OO=235.6 mm. Of course alternative sizes anddimensions are possible, in variations.

In FIG. 24 a cross-sectional view taken along line 24-24, FIG. 23 isshown. Here example dimensions would be as follows: PP=14.0 mm; QQ=26.0mm; and RR=7.0 mm.

In FIG. 24A, an enlarged view of a portion of FIG. 23 is shown. Exampledimensions would be as follows: SS=3.5 mm; TT=10.9 mm; UU=1.0 mm R; andVV=1.8 mm. In FIG. 25, molded panel arrangement 500 a is depicted.Molded panel arrangement 500 a would generally correspond to housingsection 420 and side panel 403, FIGS. 15-21. In FIG. 26, molded panelarrangement 500 a is shown in plan view. In FIG. 27 a cross-sectionalportion of FIG. 26 is shown, in FIG. 27A an enlarged portion of FIG. 26is shown. The dimensions for NN, OO, PP, QQ, RR, SS, TT, UU and VV,FIGS. 26-27A would generally be characterized as above four panel 500,since due to symmetry, for the example shown, molded arrangement 500 ais generally a mirror image of molded panel arrangement 500, for theassembly shown. Alternatives are possible.

Molded panel arrangement 500 can be molded directly to one of the sidesof the media pack 401, typically a side comprising ends of single facerstrips from which the media pack 401 is formed.

In FIG. 28, molded arrangement 500 c is depicted, which comprises one ofthe sections of the housing seal arrangement 410, in this instancesection 425 which extends across surface 412, FIG. 15. In FIG. 28 moldedarrangement 500 c is shown inverted, relative to FIG. 15.

In FIG. 29, an end elevational view taken toward end 501 is shown.

Useable dimensions would be as follows: XX=309.1 mm; YY=35.7 mm; ZZ=26.4mm; AA′=6.4 mm; BB′=22.9 mm; CC′=5° (typically at least 2°, usually atleast 3°, often 3°-10°, and typically not larger than 45°). Otherexample dimensions are DD′=13.4 mm; EE′=3°; FF′=3°; GG′=15.9 mm;HH′=24.7 mm; II′=3.0 mm; and JJ′=21.7 mm.

In FIG. 28, attention is directed to urethane rise features 503. Whensurface 412 is generally flat or nearly flat, urethane rise (expansion)is needed in the mold. The mold can be formed with apertures in aportion thereof, allowing rise to generate features shown at 503, tofacilitate manufacture.

It is noted that opposite ends 501, 502 of extension 425 can be moldedknit (sealed) with ends in the extensions 420, 421, FIGS. 22-27.

In FIG. 30 molded structure 510 corresponding to cushion or bumperarrangement 435 a, FIG. 15 is shown. In FIG. 30 structure 435 a is showninverted, relative to FIG. 15.

In FIG. 30, the following example dimensions are provided: dimensionKK′, 26.4 mm; dimension LL′, 6.4 mm; dimension MM′, 270 mm; a height of12.7 mm is shown at Z in the drawing.

FIG. 31 is an end view taken generally toward end 511. Exampledimensions would be as follows: dimension NN′, 2.0 mm; dimension OO′,21.5 mm; dimension PP′, 12.7 mm; and dimension QQ′, 6.4 mm.

It is noted that mold arrangement 510 also includes free riseprojections 513 resulting from a typical molding operation.

In FIGS. 32 and 33, molded arrangement 520 corresponding to cushion orbumper arrangement 435 b, FIG. 15, is shown. In FIG. 32, extension 435 bis shown in the same orientation as in FIG. 15. It includes free riseprojections 521. For the example arrangement as shown in FIGS. 32 and33, dimensions would be as follows: RR′=6.4 mm; SS′=26.4 mm; TT′=60.2mm; UU′=13.0 mm R; VV′=270 mm; XX′=12.7 mm; YY′=2.0 mm; ZZ′=32.7 mm;AA″=12.7 mm; and BB″=6.4 mm. FIG. 33 is taken toward end 522.

In FIGS. 34 and 35 molded arrangement 530 corresponding to housing sealsection 426, FIG. 15, is shown. In FIG. 34 it is shown in the sameorientation as viewed in FIG. 15. In FIG. 34, end 531 corresponds to end531, FIG. 15. FIG. 35 is a view taken generally toward end 531.

In FIGS. 34, 35 the dimensions indicated are as follows: CC″=309.1 mm;DD″=22.9 mm; EE″=5° (typically at least 2°, usually at least 3°, often3°-10°, typically not more than 45°). Still referring to FIG. 35, otherdimensions are as follows: DD″=22.9 mm; GG″=3°; HH″=3°; II″=15.9 mm; andJJ″=21.7 mm.

Molded extension 530 would typically be molded directly to the mediapack. Since for the cartridge of 400 depicted in FIG. 15, the surface413 to which molded arrangement 530 would be secured is a flutedsurface, the flutes will provide for the free rise (expansion) neededduring molding.

In FIG. 36, molded arrangement 540 is shown. Molded arrangement 540would correspond to bumpers 435 extending across surface 413. In thisinstance bumpers 435 c and 435 d would correspond in molded arrangement540. The two bumpers are the same. Again since they extend across afluted surface 413, free rise (expansion) projections are notspecifically provided.

FIG. 37 is a view generally taken toward end 541 of molded arrangement540.

In FIGS. 36 and 37, example dimensions are indicated as follows:LL″=270.7 mm; KK″=13.4 mm; and MM″=6.4 mm.

Of course variations from the dimensions described above can be used.

In a general molding operation, molded arrangements 500 and 500 a wouldbe provided on the media pack. The other molded arrangements would beprovided on sides 412, 413 as shown. They can be provided each in asingle molding operation or in a plurality of molding operations, aspreferred.

Of course alternate embodiments are possible, which would lead toalternate methods of manufacture if desired. The example shown, ismerely indicated to be an example of a usable approach.

It is noted that the particular housing seal arrangement 410 shown anddescribed, is segmented into the four segments described, one extendingacross each face. Alternate arrangements are possible.

VI. A General Characterization of the Filter Cartridges and Methods

In general terms, according to the present disclosure an air filtercartridge is provided. The air filter cartridge comprises a filter mediapack including a stacked construction of individual strips of filtermedia each comprising a fluted sheet secured to a facing sheet to defineinlet and outlet flow channels extending between first and secondopposite flow faces. The fluted sheet can be either flat or corrugatedperpendicularly to the extension of flutes in the fluted sheet. Ingeneral terms, the filter media pack is closed to passage of airtherethrough, from the first flow face to the opposite second flow face,without filtering passage of the air through the media.

The typical filter media pack disclosed has a blocked, stacked,configuration with four sides extending between the first and secondflow faces. As a result of the blocked, stacked, configuration, theangle of engagement between any two adjacent media pack surfaces, is 90°or nearly 90°.

In general terms the filter cartridge also includes a peripheral,perimeter, housing seal arrangement extending around the four sides ofthe media pack. The peripheral, perimeter, housing seal arrangement hasa first section extending across a first one of the four sides along apath not continuously parallel to an edge between the first side and thesecond flow face. By “not continuously parallel” in this context, it ismeant that the complete extension of the first section of the housingseal arrangement across the side is not completely parallel to the edge.Typically the entire first section of the housing seal arrangement isnot parallel to the defined edge, as shown in FIG. 15.

In general terms, the first section of the housing seal arrangement hasa first portion and second portion, the first portion being closer tothe second flow face and the second portion. For the example shown inFIG. 15, this would correspond to ends of either seal section 420 orseal section 421.

It is noted that for the particular arrangement shown in FIG. 15, thefirst section of the housing seal arrangement extends across a moldedpanel arrangement. However in a more broad general sense, there is nospecific requirement of this.

In general terms, there is provided a second housing seal section on aside opposite the first housing seal section. Typically the secondhousing seal section be a mirror image to the first housing sealsection, shown in FIGS. 15-21, although this is not required.

In general terms, the first section of the peripheral, perimeter,housing seal arrangement, when straight, will generally extend across afirst one of the four sides at a seal plane having a first angle X₁ tothe edge between the first side and the second flow face, with the firstangle X₁ being at least 2°, typically at least 3°, usually 3°-10°, andtypically not more than 45°. An example provided is about 5°.

Of course for the example shown in FIG. 15, the angle X₁ wouldcorrespond to the angle X shown. The opposite extension 421 would extendat an angle X₂, which, when extension 421 is a mirror image of extension420, would also correspond to angle X.

In general terms also according to the present disclosure, the housingseal arrangement includes a third section extending across a third sideof the media pack between the first and second sides. The third side ofthe media pack would generally extend between the first and second flowfaces.

Of course the housing seal arrangement shown also includes a fourthsection extending across a fourth side of the media pack, the fourthside of the media pack being a side position opposite to the third side.

For the particular housing seal arrangement shown, the housing sealarrangement sections are shown individually made, knitted or sealedtogether. Alternate assembly is possible, for example in which thehousing seal arrangement comprises a single, integrally molded,structure.

For the example shown, the third and fourth sections of the peripheral,perimeter housing seal arrangement generally extend with a seal plane:extending parallel to edges of the media pack corresponding to thejuncture between the sides on which each of the third and fourthsections are positioned, and the flow faces; and, extending at an angleof less than 90°, to the associated sides. An example of this is shownin FIGS. 15-21. Of course alternatives are possible.

More specifically, for the particular arrangement shown, the sealarrangement defines a central seal plane. As a result the first andsecond sections of the peripheral, perimeter, housing seal arrangementas defined above, would extend, as shown in the cross-sectional figuresdepicted, with a central seal plane extending generally orthogonal tothe associated sides of the media pack. On the other hand the third andfourth sections of the peripheral, perimeter, housing seal arrangementare shown extending at an acute angle of less than 90° outwardly fromassociated sides, typically no more than 88° (90°-2°).

Herein in this context reference is meant to seal extension disregardingdraft angles on the seal, with the reference being to a plane bisectingeach seal extension as it projects outwardly from the media pack.

An example shown, a non-seal cushion or bumper arrangements extendingacross selected sides of the media pack are shown. For the exampledepicted in FIGS. 15-21, two cushion or bumper extensions are positionedin extension across a pair of opposite sides 412, 413 which extendbetween the sides on which the molded panels 402, 403 are provided. Inmore general terms, the cushions arrangements extend across sides of themedia pack 401 which comprise exposed media. Example of specificarrangements are shown and described.

For the examples described, the opposite panels which cover ends of thesingle facer strips, are molded-in-place panels.

Examples of molded housing seal arrangements and methods for making themare described.

In general terms according to the present disclosure an air cleanerassembly is provided which includes a housing having a base and servicecover. The base is described as having a first outwardly directed sealsupport flange; and the service cover is defined as having a secondoutwardly directed seal support flange. An air filter cartridge ingeneral terms described above, is positioned in the air cleaner assemblywith the housing seal arrangement positioned and sealed between the sealsupport flange on the base and the seal support flange of the servicecover.

An example support flange arrangement is described in which the firstsupport flange includes a first seal edge (blunt knife blade) projectionthat is directed into the housing seal arrangement during sealing; andthe second seal support flange includes a second seal edge (blunt knifeblade) projection which extends into the housing seal arrangement,during sealing. A preferred arrangement in which the seal edgeprojection of the downstream side of the housing (in the example shownthe base), is positioned radially outwardly from the media pack furtherthan the seal edge projection positioned on the downstream side of thehousing (in the example shown the housing cover).

For the particular air cleaner assembly shown, the housing base includesa dirty air inlet arrangement, the service cover includes a clean airoutlet arrangement, and the air flow is generally directed upwardlythrough an internally received filter cartridge.

VII. A Second Example of an Air Cleaner Assembly Utilizing Principles asDescribed Herein, FIGS. 38-55.

In the air cleaner arrangement and features of FIGS. 38-55, many of thegeneral principles described hereinabove are applied in a particularexample, in some instances with additional features. In FIGS. 38-42features of an example air cleaner assembly are shown. In FIGS. 43-55,features of a removable and replaceable (serviceable) filter cartridgefor utilization in the air cleaner of FIGS. 38-42, are depicted.

In FIG. 38, at reference numeral 600, an air cleaner arrangementincluding features according to the present disclosure is provided. Theair cleaner arrangement 600 comprises a housing 601 including a first,in this instance inlet or base section 602 and a second, in thisinstance outlet or cover, section 603. The inlet section 602 and outletsection 603 are secured to one another along a housing separation region605. For the sample shown, outlet section 603 is positioned on inlet orbase section 602 as a cover.

Releasable clamps 607 are provided for removably securing the sections602, 603 to one another along the separation region 605. The drawingsare schematic with respect to the clamps 607, and they are shownpositioned approximately where they would be used in the finalarrangement. In some instances the clamps 607 may be mounted on mountssuch as shown at 607 a, indicating that each could be positioned shiftedslightly laterally from its depicted position, in the actual product.

Still referring to FIG. 38, at 611 an inlet arrangement, in thisinstance an inlet tube 611 a is positioned for air flow inlet into aninterior of housing 601. The inlet tube 611 a, in this example, isintegral with a remainder of housing section 602.

At 612 an outlet arrangement, in this instance an outlet tube 612 a, isdepicted, providing for air flow in the interior of housing 601. In theexample shown, outlet tube 612 a is integral with outlet section 603.

Normal filtering air flow, then is: (a) into inlet tube 611 a; (b) intohousing section 602; (c) through an internally received filter cartridgediscussed below; and (d) with the filtered air then flowing into section603 and exiting therefrom through outlet tube 612 a. For the exampleshown, the air is directed under the filter cartridge, upwardly throughthe filter cartridge, for filtering, and then out of the housing 601.

A variety of materials can be utilized for housing 601. Typically,sections 602 and 603 are molded from a plastic material, althoughalternatives are possible. The latches 607 are typically wire.

In FIGS. 38-41, the housing base or inlet section 602 includes: a firstwall 602 a, having inlet section 611 therein; opposite wall 602 b,having outlet tube 612 (of cover 603) thereabove; a first side wall 602c; and, an opposite second side wall 602 d. Further, the base sectionincludes a bottom 602 e. The bottom 602 e is contoured and configured,to facilitate air flow into a media pack contained within the housing601.

Still referring to FIG. 38, housing section 602 is provided with amounting or mounting post arrangement 614 including mounting pads 615thereon. The particular number and arrangement of mounting pads 615would typically be customized for a mounting location in a particularvehicle or equipment, such as on an engine block or frame component. Thepads 615 provide for support of the air cleaner 600 in a desiredorientation for operation. For the example shown in FIG. 38, the typicalorientation for operation would be as shown, with the outlet section 603positioned above the inlet section 602.

In FIG. 38, example dimensions are provided as follows: AB=436.8 mm;AC=375 mm; and AD=140 mm. These dimensions are examples, and a varietyof alternate sized arrangements can be used. The dimensions describedfor FIGS. 38-55 are usable, for example, as an air cleaner for a vehiclesuch as a light duty pick-up, twin turbo, having a rated air flowtherethrough on the order of about 800 cfm.

Attention is now directed to FIG. 39 in which an end elevational view(toward end 602 a) is depicted, the view being toward inlet arrangement611. Referring to FIG. 39, and looking into inlet tube 611 a, a portionof a removable and replaceable filter cartridge 625 is viewable. Such afilter cartridge 625 is sometimes referred to as a “service part”, sinceafter a period of use in air cleaner 600, cover, outlet, section 603would be separated from section 602, the filter cartridge 625 would beremoved and the air cleaner 600 would be serviced, typically byinstallation of a new cartridge 625.

Also referring to FIG. 39, region 630 of housing section 603 is viewablewith a curved, shape helping to direct (funnel) air flow from the filtercartridge 625 toward outlet tube 612. Such a curved arrangement forchanging the direction of air flow and directing it toward an outlettube 612, will be characterized herein, in general terms, as an outletair scoop or outlet air funnel configuration. Similarly, bottom 602 e ofinlet section 602 has an inlet air scoop or inlet air funnelconfiguration.

Dimensions indicated in FIG. 39, for the example shown, are as follows:BA=115.5 mm; BB=235.9 mm; BC=28.8 mm; and BD=58 mm.

Attention is now directed to FIG. 40, a top plan view of air cleaner600. Referring to FIG. 40, it can be seen that for the example aircleaner 600 provided, four clamps 607 are used to secure housing section603 in place, although alternatives are possible.

Still referring to FIG. 40, at 631 a mounting arrangement in outlet 612is provided, for mounting equipment such as a pressure indicator withinassembly 600. Also, in some instances, a mass air flow sensor (MAFS) canbe positioned either in outlet arrangement 612 or in duct workdownstream.

In FIGS. 38-40, various ribbed structures 635 are depicted in thehousing 601. The ribbed structures provide for such functions asdecorative appearance and strengthening housing components involved. InFIG. 38 at 635 a and 635 b, a shelf arrangement comprising oppositeshelves in base or inlet section 602 is provided by contours in base602. These will be used to support the internal filter cartridge 625, asdiscussed below.

In FIG. 40, indicated dimensions for the example described are asfollows: CA=338.5 mm; and, CB=9 mm.

Attention is now directed to FIG. 41, a cross-sectional view of aircleaner 600 taken along line 41-41, FIG. 38. Referring to FIG. 41,filter cartridge 625 is seen positioned within interior 601 a of housing601. The filter cartridge 625 comprises a media pack arrangement 636 andhousing seal arrangement 640. The media pack arrangement 636 generallycomprises a media pack 636 a having opposite side panels 637, 638 ofwhich only panel 638 is partially viewable in FIG. 41. The media packarrangement 636 is discussed in greater detail below.

The housing seal arrangement 640 is a peripheral, perimeter sealarrangement and includes a pinch seal flange 641 extending (andprojecting outwardly) around the media pack arrangement 636. The sealflange 641 is configured to be positioned between flange arrangements atthe housing separation region 605, for formation of an axial pinch seal.The term “axial” in this context, is meant to refer to a seal thatoperates with a compression or pinch in a direction generally in linewith the direction of air flow, see arrow 639, through media packarrangement 636, as opposed to the direction toward or away from mediapack 636.

For the example shown, the housing seal arrangement 40 is amolded-in-place housing seal arrangement, meaning it is molded directlyto the media pack arrangement 636. Further, the housing seal arrangement640, for the example shown, is molded from a single polymeric material,such as a polyurethane material, for example polyurethane foam. That is,the housing seal arrangement 640 includes no preformed rigid structuresembedded therein, in the preferred example depicted. Such amolded-in-place housing seal arrangement will sometimes be described asconsisting essentially of the polymeric material from which it ismolded.

Still referring to FIG. 41, the media pack 636 a includes a first,lower, in this instance inlet, face 645, and, a second, opposite, inthis instance outlet face 646. The direction of air flow duringfiltering is generally from inlet face 645 to outlet face 646, as shownby arrow 639.

The filter cartridge 625 is discussed in further detail below, inconnection with FIGS. 43-55. However before turning to those figures,attention is directed to FIG. 42, an enlarged fragmentary view of aportion of FIG. 41, and providing for an understanding of housing sealarrangement 640 in greater detail. It is noted that FIG. 42 isschematic.

Referring to FIG. 42 housing seal arrangement 640 is depicted mounted onmedia pack arrangement 636. The housing seal arrangement 640 wouldtypically be directly mounted on the media pack 636 a, in extensionacross those sides which do not include a side piece 637, 638. By theterm “directly” it is meant that the housing seal arrangement 636 issecured in contact with the media of the media pack along those sides towhich it is directly mounted. That is, there is no preformed structuralmember between the housing seal arrangement and the media, along twosides, in a typical preferred instruction. When extending across sidepieces 637, 638, the housing seal arrangement 640 would generally besecured directly to the side pieces 637, 638, with the side pieces 637,638 being secured to the media pack 636 a.

Referring to FIG. 42, the housing seal arrangement 640 comprises pinchseal flange 641 and base 650. The two are typically molded integral withone another; housing seal arrangement 640 typically being molded from asingle polymeric material such as a foamed polyurethane. Pinch sealflange 641 is positioned on base 650 in a form defining trough 660between a portion of the pinch flange 641 and the media pack arrangement636 (and media pack 636 a).

The trough 660 is sized and positioned as a receiving trough to receive,extending therein, a projection flange 665 on housing cover section 603.That is, during installation, in a typical example, a flange 665 on ahousing section, in this instance section 603, projects into trough 660to a location between a portion of the pinch flange 641 and the mediapack arrangement 636. Projection of flange 665 into trough 660, betweenpinch flange 641 and the media pack arrangement 636 provides for avariety of effects including: facilitating centering of filter cartridge636 in place, during installation; and helping to ensure that a propercartridge 625 is used and is properly oriented in the housing 601.

Although alternatives are possible, the trough 660 is typically at least4 mm deep at its deepest extension, usually at least 5 mm deep, and forthe example shown 6-12 mm deep. The maximum depth of extension is amatter of choice, for the application involved, but typically will notexceed 14 mm.

Still referring to FIG. 42, housing section 602 is provided with flangearrangement 670 thereon comprising: receiver section 671, sized andshaped to accommodate base 650; radially outwardly directed flangesection 672; and, axially directed outer rim projection or section 673.The outer rim projection 673 extends toward cover section 603. Outer rimprojection section 673 and outwardly directed flange 672 together form atwo-sided pocket 675 for receipt therein of seal flange 641, duringinstallation.

Housing section 603 includes: radially, outwardly directed flange 680;and axially directed outer rim projection 681 positioned on flange 680.The rim projection 681 extends toward base 602. The flange 680 and rimprojection 681 together form a two-sided pocket 685 for fitting overseal flange 641, during installation. The pocket 685 is sized such thatwhen clamping of clamp 607 occurs, projection 673 will engage (bottomout) against flange 680, at a level of appropriate compression for pinchflange 641. In FIG. 42, a typical amount of compression is indicated byoverlap between pinch flange 641 and housing flange 680.

Still referring to FIG. 42, it is noted that flange 680 includes acentral, axial, seal projection, edge or bead 690 thereon, positioned toproject axially into seal flange 641, during sealing, to facilitateformation of a seal. The seal bead 680 generally projects, relative toan adjacent portion of flange 680, sufficiently to press into the sealmaterial 641 a distance corresponding to 2%, typically at least 3% andusually at least 4% of the maximum thickness of region 641, when notcompressed.

Typically and preferably both bead 690 and projection 665 extendcompletely around media pack arrangement 626, during installation.

Still referring to FIG. 42, it is noted that the pinched flange 641 isgenerally sized to be compressed at least 2%, typically at least 3% andusually at least 4% in overall thickness from its uncompressed position,during sealing and compression. This latter description is meant torefer to the portions of the seal lip 641 not engaged by the bead 690.

Referring now to FIG. 43, reference number 625 indicates the removableand replaceable, i.e., serviceable, filter cartridge installable withinair cleaner 600, generally in accord with FIGS. 41 and 42. As previouslyindicated, filter cartridge 625 comprises media pack arrangement 636 andhousing seal arrangement 640. The media pack arrangement 636 comprisesmedia pack 636 a and two opposite side panels 637, 638. The typicalmedia pack 636 a would comprise a stack of strips of corrugated mediasecured to facing media appropriately to form opposite inlet and outletfaces 645, 646 respectively. As a result of flute seal arrangementswithin the media pack 636, a plurality of inlet flutes would extendbetween the faces 645, 646 and a plurality of outlet flutes would extendbetween the faces 645, 646 with: the inlet flutes open adjacent theinlet face 645 and closed adjacent the outlet face 646; and, with theoutlet flutes open adjacent the outlet face 646 and closed adjacent theinlet face 645. The media pack 636 a would generally be closed todirection of unfiltered air between faces 645, 646. Thus, in order forair that is passed into inlet face 645 to pass outwardly from outletface 646, (on opposite side of seal arrangement 640) the air must flowthrough a portion of the media. This is typical z-filter configurationas discussed above.

The housing seal arrangement 640 as previously discussed, comprisespinch flange 641 and base 650. Trough 660 is positioned between aportion of pinch flange 641 and the media pack arrangement 636.

In FIG. 44, a side elevational view of the cartridge 625 is provided,the view being toward side panel 638. Referring to FIG. 44, it can beseen that the example pinch seal 641 is planar and a plane of pinch seal641 extends at an angle DA relative to a plane of outlet face 646, thatis greater than 0°. The angle DA, (as previously discussed for angle X,FIG. 1 a), is generally at least 2°, typically at least 3°, typicallynot larger than 80°, usually not more than 45°, and as an example,3°-10°, inclusive. For the example shown, the angle DA is 10°. It istypically within the range of 5°-15°. (Some of the techniques describedherein can be applied with a pinch seal 641 that is non-planar.)

From the above, it will be understood that for the example shown thepinch seal 641 generally defines a plane, which extends at an anglegreater than 0°, typically greater than 2°, etc., relative to theopposite flow faces 645, 646 of the media pack 636 a. Alternatearrangements are possible, for example wherein portions of the sealarrangement are in different planes.

Still referring to FIG. 44, it is noted that side panel 638 includes anupper edge 638 a, a lower edge 638 b and opposite side edges 638 c and638 d. Edge 638 a is formed with a projection arrangement 652, in thisinstance spaced bumpers, that project axially beyond media pack face646, in the example shown, by a distance DB of at least 0.5 mm, usuallyat least 1 mm. Typically the amount of extension DB would be at least1.5 mm, for example 1.5-3.5 mm. For the example shown, the dimension DBis 2.3 mm. The dimension DB allows sections 652 to operate as bumpers.

Similarly, the bottom of edge 638 b includes a projection arrangement652, in this instance spaced bumpers. The projection arrangement 652 inside edge 638 b, extend beyond surface 645 a distance analogous to DB,i.e., at least 0.5 mm, usually at least 1 mm, typically at least 1.5 mm,and usually 1.5 mm-3.5 mm, for example 2.3 mm.

In a typical arrangement, the opposite panel 637, FIG. 43, is identicalto panel 638, but mounted as a mirror image. Thus, it too has top andbottom edges 637 a, 637 b, FIG. 43, and side edges 637 c, 637 d with:top and bottom edges 637 a, 637 b including spaced bumpers 652 extendingaxially beyond media pack faces 646, 645. When installed, one or more ofedges 637 a, 637 b, 638 a, and 638 b can engage a shelf arrangement tosupport cartridge 625. For example referring to FIG. 38, edge 637 bwould rest on shelf 635 a, and edge 638 b would rest on shelf 635 b.This provides for a support of cartridge 625 within interior 601 a ofhousing 601, so that the cartridge 625 is not suspended by the pinchseal 641. This will stabilize the cartridge 625 when installed, againstdamage from vibration and shock, during use.

Referring to FIG. 44, dimension DC would be 235 mm, for the exampleshown.

Attention is now directed to FIG. 45, which a top plan view of cartridge625 is depicted, toward outlet face 646. In FIG. 40 the indicateddimensions, for the example described in this section is as follows:EA=265.2 mm; EB=230.4 mm; EC=272.7 mm; and ED=312.3 mm.

Attention is now directed to FIG. 46, a cross sectional view ofcartridge 625 taken along line 46-46, FIG. 45. In FIG. 46 the exampledimensions indicated are as follows: FA=131.6 mm; FB=127 mm; andFC=271.2 mm.

From the dimension FB of 127 mm, it will be understood that thetechniques described herein are particularly well suited for media packsthat are relatively thick in extension between the opposite flow faces645, 646. Although the techniques can be applied in alternateconfigurations, they are particularly well adapted for media packs withthe dimension between the opposite flow faces 645, 646 of at least 50mm, and typically 90 mm or more.

Attention is now directed to FIG. 47, a cross sectional view ofcartridge 625 taken generally along line 47-47, FIG. 47. Referring toFIG. 47, the dotted line location at 680 indicates the location of thestacking beads that seal closed the outlet flutes at a region adjacentto inlet face 645. The dotted line 681 indicates the single facer beadlocation sealing the inlet flutes closed adjacent to outlet face 646.

The two dotted lines for the stacking beads, in 680, indicate that thestacking bead is recessed from face 645, but it can still becharacterized as adjacent thereto. The single dotted line 681 for thesingle facer bead location, indicates that the single facer bead abutsthe outlet face 646, as it would when constructed in the mannerdescribed hereinabove in which the single facer bead is cut in halfduring a manufacturing process, leaving it flush with the face of theresulting media pack.

Attention is now directed to FIG. 48, a plan view of cartridge of FIG. 5generally directed toward side 665, FIG. 43. FIG. 49 is an opposite planview to FIG. 48, the view generally being directed toward side 666, FIG.44.

For the example shown, surfaces 665, 666 are not covered by any moldedpanel arrangement or side piece, except at edges, but rather compriseexposed surfaces of single facer material, either fluted or facingsheet, with seal arrangement 640 extending thereacross. In somearrangements, if desired, protective materials can be placed oversurfaces 665, 666 if desired. In addition, or alternatively, molded sidepanels or bumpers can be provided along faces 665, 666. However, it isanticipated in a typical example, surfaces 665, 666 will generally beleft as exposed media or single face surfaces, for convenience.

In FIG. 49, the example dimensions are as follows: GA=312.3 mm; andGB=268.2 mm.

Attention is now directed to FIG. 50. FIG. 50 is generally a side planview of the side panels 637, 638. The panels 637, 638 would generally beidentical, and positioned as mirror images on the media pack 637 a. InFIG. 50, the example dimensions are as follows: HA=207.5 mm; HB=147.5mm; HC=87.5 mm; HD=27.5 mm; HE=11.7 mm; HF=3.0 mm radius; HG=3.9 mm;HI=131.6 mm; HJ=103.6 mm; HK=65.8 mm; HL=28 mm; HM=235 mm; HN=117.5 mm;HO=28 mm; and HP=103.6 mm. Other dimensions can be obtained based uponthe symmetry and scale of the drawing, FIG. 50.

Normally, the media panels 637, 638, would be molded directly onto themedia pack 636 a, in a two step molding operation: a first step to formone of the panels 637, 638 and a second step to form the opposite panel638, 637.

Typically the material from which the side panel 637, 638 are formed, isa foamed polyurethane, as discussed below.

In FIGS. 51-55, the housing seal arrangement 640, and features thereof,are shown. The housing seal arrangement 640, of course, would typicallyform molded directly to the media pack arrangement 636, in extensionaround the media pack arrangement 636 a and side panels 637, 638. InFIG. 51, the housing seal arrangement 640 is depicted schematically,without the media pack 636, secured thereto.

In FIG. 52, a top plan view of the housing seal arrangement 640 isdepicted. Dimensions in the example of FIG. 52 are as follows: IA=312.3mm; IB=156.2 mm; IC=275.1 mm; and ID=137.5 mm.

In FIG. 53, a cross sectional view taken along line 53-53, FIG. 52, isshown. In FIG. 54 the dimensions indicated are as follows: JA=271.2 mm;and JB=37.1 mm.

In FIG. 54, an enlarged fragmentary view of a portion of FIG. 53. Thedimensions indicated in FIG. 54 are as follows: KA=19.6 mm; KB=16.8 mm;KC=12.9 mm; KD=12.3 mm; KE=15.4 mm; KF=7.3 mm; KG=1.5 mm radius; KH=3.0mm; KI=3 mm; and KJ=9 mm.

In FIG. 55 a cross sectional view taken along line 55-55, FIG. 52, isshown. Referring to FIG. 55 the dimensions indicated are as follows:LA=230.4 mm; LB=37.1 mm; LC=10°; LD=16°; and LE=16°.

The housing seal arrangement 640 (and the side moldings 637, 638) can beprovided from a variety of polymeric materials. When separately molded,it is not required that the panels 637, 638 and housing seal arrangement640 all be the same, although typically they will be. An examplematerial useable for both the seal and the side moldings describedherein is polyurethane. An example polyurethane characterized is afoamed polyurethane which will increase in volume during use. Preferredones increase by at least 40% in volume, to fill the mold cavities(typically at least 80% in volume) and having an as-molded density of nogreater than 30 lbs/cu.ft (0.48 g/cc), typically no greater than 22lbs/cu.ft. (0.35 g/cc) and usually with in the range of 10 lbs/cu.ft(0.16 g/cc) to 22 lbs/cu.ft (0.35 g/cc); and, a hardness (Shore A) of atest sample typically of not greater than 30, preferably not greaterthan 25 and typically within the range of 10 to 22. Of coursepolyurethanes outside of this range can be used, but the characterizedones are advantageous for manufacturing and handling.

Referring to FIGS. 39 and 41, it is noted that the cartridge 625 (withthe housing seal arrangement 640 extending with a pinched sealarrangement 641 at an angle of greater than 0°, for example at least 2°,typically 5-15° inclusive, in the example shown 10°, relative to face646 of the media pack 636 a), is positioned within interior 601 ofhousing 601 such that the faces 645, 646 of the media pack 636 a areslanted across a direction between the inlet arrangement 611 and theoutlet arrangement 612. That is, the media pack 636 a is not tiltedtoward the outlet arrangement 612 a, nor is it slanted away from theoutlet arrangement 612 a, rather it is slanted in a direction generallyacross a direction corresponding to a direction between walls 602 a, 602b of section 602. Alternatively stated, the slant of faces 645, 646 isbetween sides 602 c, 602 d of section 602.

In still an alternate statement of the same concept to the previousparagraph, when positioned in the housing 601, the cartridge 625 ispositioned with one of the molded side panels 637, and a section of theseal arrangement 640 extending thereacross, directed toward the sidewall 602 a, in which the inlet arrangement 611 is positioned; and, withan opposite molded side panel 638, and a section of the housing sealarrangement 640 extending thereacross, facing toward the opposite sidewall 602 b of the housing seal. The sections of the housing peripheralseal arrangement 640 which extend across these portions of the mediapack arrangements, are angled relative to the outlet face 646, andopposite edges of the outlet face 646, by angle DA, FIG. 44.

It is noted that the filter cartridge 625, FIG. 41, is typicallypositioned within the housing interior 601, such that at least 5%,typically at least 10% and usually at least 15% of the volume of pack636 a is positioned in the housing cover section 603, typically with anapex 700, FIG. 41, projecting furthest upwardly into cover section 603.A ridge corresponding to the apex 700 would generally extend in adirection between side walls 602 a, 602 b, FIG. 38, but above thehighest reach of those side walls 602 a, 602 b.

Alternate arrangements, in which the media pack 636 a is tipped towardor away from the outlet tube 612 a are possible. An example is describedin U.S. provisional application 60/651,838 already incorporated hereinby reference and to which a claim of priority was made.

It is noted that although alternatives are contemplated, the particularexample filter cartridge as described herein include housing sealarrangements that are molded-in-place. By this term “molded-in-place”,it is meant that the housing seal arrangement is molded directly ontothe media arrangement. Thus, the housing seal arrangement 640 is moldeddirectly to, and in contact with the exposed media sides 665, 666 of themedia pack and then sides with side panels 637, 638 thereon.Alternatives are contemplated and discussed, but the example shownutilize these features.

Further, although alternatives are contemplated, for the specificexamples described here in the molded-in-place housing seal arrangementcomprises a single molded polymeric material, and includes no preformed,rigid, structure embedded therein. Thus, the example housing sealarrangement as described, can be characterized as consisting essentiallyof molded polymeric material, and in particular molded polyurethanematerial (typically molded polyurethane foam). An advantage to this isthat no adhesive is needed to secure the media pack to the housing sealarrangement.

For the first example filter cartridge described in FIG. 15, themolded-in-place housing seal arrangement is constructed in foursegments, from four moldings. In the second described example of FIG.43, the molded-in-place housing seal arrangement is molded as a singleintegral unit, in one molding operation.

In the example of FIG. 43, the housing seal arrangement is described ashaving a base and a pinch seal lip. The two are molded integral with oneanother, meaning they are molded from a polymeric material in a singlemold, with the two portions integral with one another as a result of themolding. They are not separately formed components.

1. An air filter cartridge comprising: (a) a filter media pack havingfirst and second opposite flow faces; the filter media pack comprising astacked construction of individual strips of filter media comprisingfluted media secured to facing media to define inlet and outlet flowchannels extending between the first and second, opposite, flow faces;(i) the filter media pack being closed to passage of air therethrough,from the first flow face to the opposite second flow face, withoutfiltering passage through the media; (ii) the filter media pack having astacked configuration with four sides extending between the first andsecond opposite flow faces; and, (iii) the four sides defining first andsecond, opposite, sides; and, third and fourth, opposite, sides; (b)first and second molded-in-place side panels; (i) the first and secondside panels being positioned, respectively, on the first and secondsides of the filter media pack; and, (c) a housing seal arrangementcomprising a molded-in-place, peripheral, perimeter, seal extendingaround the four sides of the media pack and across the first and secondside panels; (i) the housing seal arrangement being positioned spacedfrom at least one of the first and second, opposite, flow faces; (ii)the peripheral, perimeter, seal having a first section extending acrossa first one of the side panels along a path not continuously parallel toa media pack edge between a corresponding side of the media pack and thesecond flow face; (A) the first section extending completely across thefirst one of the side panels at a first angle X₁, to the media pack edgebetween the first side and the second flow face of at least 2°; and,(iii) the housing seal arrangement including a base and a pinch seallip; (A) the pinch seal lip being positioned on, and molded integralwith, the base; and, (B) the base and pinch seal lip defining a troughbetween at least a portion of the pinch seal lip and the media pack. 2.An air filter cartridge according to claim 1 wherein: (a) the housingseal arrangement is positioned with the pinch seal lip spaced from eachof the first and second, opposite, flow faces.
 3. An air filtercartridge according to claim 1 wherein: (a) the media pack has ablocked, stacked, configuration wherein the media pack is configured asa rectangular block in which all sides and faces are at 90° relative toall adjoining sides and faces.
 4. An air filter cartridge according toclaim 1 wherein: (a) the first angle X₁ is no greater than 45°.
 5. Anair filter cartridge according to claim 4 wherein: (a) the first angleX₁ is within the range of 5° - 15°.
 6. An air filter cartridge accordingto claim 5 wherein: (a) the first angle X₁ is 10°.
 7. An air filtercartridge according to claim 1 wherein: (a) the peripheral, perimeter,housing seal arrangement has a second section extending across a secondone of the four sides along a path not continuously parallel to an edgebetween the second side and the second flow face; (i) the second sectionof the peripheral, perimeter, housing seal arrangement extendingcompletely across the second one of the four sides at a second angle X₂to the edge between the second side and the second flow face; the angleX₂ being the same as the angle X₁.
 8. An air filter cartridge accordingto claim 7 wherein: (a) the first section and the second sections of thehousing seal arrangement are positioned along opposite sides of themedia pack as mirror images of one another.
 9. An air filter cartridgeaccording to claim 1 including: (a) first and second side panelspositioned on opposite sides of the media pack.
 10. An air filtercartridge according to claim 9 wherein: (a) the first side panel ispositioned on the first one of the four sides of the media pack; (b) thesecond side panel is positioned on the second one of the four sides ofthe media pack and opposite the first side panel; and, (c) theperipheral, perimeter, housing seal arrangement is positioned extendingaround a media pack arrangement comprising the media pack and sidepanels.
 11. An air filter cartridge according to claim 9 wherein: (a)the side panels comprise molded-in-place side panels of foamedpolyurethane sealing ends of strips of fluted media secured to facingmedia; and, (b) the peripheral, perimeter, housing seal arrangementcomprises a molded-in-place arrangement consisting essentially of foamedpolyurethane.
 12. An air filter cartridge according to claim 1 wherein:(a) the trough extends continuously, peripherally, around the mediapack.
 13. An air filter cartridge according to claim 1 wherein: (a) theperipheral, perimeter, housing seal arrangement includes a third sectionextending across a third side of the media pack; (i) the third side ofthe media pack being positioned between the first and second sides; and,(ii) the third side of the media pack extending between the first andsecond flow faces; and (iii) the third section of the peripheral,perimeter, housing seal arrangement extending across the third side ofthe media pack in a direction of extension generally parallel to an edgeof the media pack extends between the third side and the second flowface and in direct contact with the media; and, (b) the peripheral,perimeter, housing seal arrangement includes a fourth section extendingacross a fourth side of the media pack; (i) the fourth side of the mediapack being positioned opposite the third side; and, (ii) the fourthsection of the peripheral, perimeter, housing seal arrangement extendsacross the fourth side of the media pack in a direction of extensiongenerally parallel to an edge of the media pack between the fourth sideand the second flow face.
 14. An air cleaner assembly comprising: (a) ahousing having a base and service cover; (i) the base having a firstoutwardly directed seal support flange; and, (ii) the service coverhaving a second outwardly directed seal support flange; and (b) an airfilter cartridge operably positioned within the housing with a portionof a peripheral perimeter housing seal arrangement compressed betweenthe seal support flanges; the air filter cartridge comprising: (i) afilter media pack having first and second opposite flow faces; thefilter media pack comprising a stacked construction of individual stripsof filter media comprising fluted media secured to facing media todefine inlet and outlet flow channels extending between the first andsecond, opposite, flow faces; (A) the filter media pack being closed topassage of air therethrough, from the first flow face to the oppositesecond flow face, without filtering passage through the media; (B) thefilter media pack having a stacked configuration with four sidesextending between the first and second opposite flow faces; and, (C) thefour sides defining first and second, opposite, sides; and, third andfourth, opposite, sides; (ii) first and second molded-in-place sidepanels; (A) the first and second side panels being positioned,respectively, on the first and second sides of the filter media pack;and, (iii) a housing seal arrangement comprising a molded-in-place,peripheral, perimeter, seal extending around the four sides of the mediapack and across the first and second side panels; (A) the housing sealarrangement being positioned spaced from at least one of the first andsecond, opposite, flow faces; (B) the peripheral, perimeter, seal havinga first section extending across a first one of the side panels along apath not continuously parallel to a media pack edge between acorresponding side of the media pack and the second flow face; (1) thefirst section extending completely across the first one of the sidepanels at a first angle X₁, to the media pack edge between the firstside and the second flow face of at least 2°; and, (C) the housing sealarrangement including a base and a pinch seal lip; (1) the pinch seallip being positioned on, and molded integral with, the base; and, (2)the base and pinch seal lip defining a trough between at least a portionof the pinch seal lip and the media pack.
 15. An air cleaner assemblyaccording to claim 14 wherein: (a) the service cover includes a sealprojection positioned on the second outwardly directed seal supportflange; (i) the seal projection extending completely around a media packof the air filter cartridge and being pressed into a pinch seal lipportion of the peripheral perimeter housing seal arrangement.
 16. An aircleaner assembly according to claim 14 wherein: (a) the housing includesa peripheral projection extending into the trough between the pinch seallip and the media pack.
 17. An air cleaner assembly according to claim14 wherein: (a) the housing base includes an air flow inlet arrangementoriented to direct air flow underneath the filter cartridge; and, (b)the service cover includes an air flow outlet arrangement.
 18. An aircleaner assembly according to claim 17 wherein: (a) the housing baseincludes a first wall having the air flow inlet arrangementtherethrough, an opposite second wall, a bottom and opposite side walls;and, (b) the filter cartridge is positioned with the first section ofthe peripheral, perimeter, housing seal arrangement directed toward thefirst wall of the housing base.